Optimax75-115hp (1 5L)

Manual Outline
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
90-8M0047659 JULY 2010

Serial Number 0T801000 and Above
www.mercurymarine.com.au www.mercurymarine.com www.marinepower.com

132-140 Frankston Road P.O. Box 1939 (Parc Industriel de Petit-Rechain)
Dandenong, Victoria 3164 Australia Fond du Lac, WI 54936-1939 USA B-4800 Verviers, Belgium
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.
IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.
This manual has been written and published by the Service Department of Mercury Marine to aid our dealers mechanics and
company service personnel when servicing the products described herein. We reserve the right to make changes to this manual
without prior notification.
2009, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers,
Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Bravo Two, Pro Max, OptiMax, SportJet, KPlanes, MerCathode,
RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, VesselView, and SmartCraft logo are all
registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick
Corporation.
It is assumed that these personnel are familiar with marine product servicing procedures. Furthermore, it is assumed that they
have been trained in the recommended service procedures of Mercury Marine Power Products, including the use of mechanics
common hand tools and the special Mercury Marine or recommended tools from other suppliers.
We could not possibly know of and advise the marine trade of all conceivable procedures and of the possible hazards and/or
results of each method. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the
manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered.
All information, illustrations, and specifications contained in this manual are based on the latest product information available at
the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these
products.
Refer to dealer service bulletins, operation maintenance and warranty manuals, and installation manuals for other pertinent
information concerning the products described in this manual.
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.
Cleanliness and Care of Product

A Mercury Marine Power Product is a combination of many machined, honed, polished, and lapped surfaces with tolerances
measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. It
should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure.
This is considered standard shop practice even if not specifically stated.
Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed
in the same locations and with the same mating surfaces as when removed.
Personnel should not work on or under an engine that is suspended. Engines should be attached to work stands, or lowered to
ground as soon as possible.
Page ii
Page iv
Specifications
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
90-8M0047659 JULY 2010 Page 1A-1

Specifications
75/90/115/115 Pro XS/125 OptiMax Master Specifications

General Specifications
Model Specifications
55.2 kW (75 hp)
66.2 kW (90 hp)
Kilowatts (Horsepower)
84.6 kW (115 hp)
93.2 kW (125 hp)
Weight
50.8 cm (20 in.) 163.3 kg (360 lb)
63.5 cm (25 in.) 168.7 kg (372 lb)
76.2 cm (30 in.) N/A
Displacement (all hp) 1.5L (92.9 cu. in.)
RPM
Idle 650 25 RPM
WOT 50005750 RPM
Limiter 5800 RPM
Induction system Throttle body aspiration
Fuel system Computer controlled sequential multiport electronic fuel injection
Ignition system SmartCraft propulsion control module (PCM) digital inductive
Charging system Regulated beltdriven 60 amp alternator
Exhaust system Through the propeller
Cooling system Water cooled thermostat with pressure control
Lubrication system Multiport oil injection
Engine reservoir capacity 4.72 liter (5 U.S. Quart)
External tank (optional) 11.4 liter (12 U.S. Quart)
Engine control system SmartCraft propulsion control module (PCM)
Trim system
Maximum tilt range 75
Maximum trim range 20
Page 1A-2 90-8M0047659 JULY 2010

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
Type Digital inductive
Firing order 123
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
90-8M0047659 JULY 2010 Page 1A-3

Specifications
Charging and Starting Specifications

Alternator output (regulated)
Output at the battery at 2000 RPM 3238 amps
Output at the alternator at 2000 RPM 5260 amps
Voltage set point 14.5 0.25 volts
Regulator current draw1.
Ignition switch "OFF" 0.585 mA
Ignition switch "ON" 150.0 mA
Starter draw
Under load 200 amps
No load 65 amps
Average engine RPM when cranking 300325 RPM
Starter solenoid current draw at 12.6 volts
Pull in coil 40 amps
Hold in coil 10 amps
Start solenoid current draw 4 amps
Starter brush length (minimum) 6.35 mm (0.25 in.)
Battery rating (minimum)
Marine cranking amperes 1000
Cold cranking amperes 800
Ampere hour (Ah) 180
Air Compressor Specifications

Air compressor type Reciprocating piston
Air compressor output (1.14:1 ratio with engine RPM) at idle 655 kPa (95 psi)
Displacement 60 cc (3.66 cu. in.)
Cylinder bore 52.0 mm (2.0472 in.)
Cylinder bore taper (maximum) 0.025 mm (0.001 in.)
Cylinder bore out of round (maximum) 0.025 mm (0.001 in.)
Cylinder bore type Cast iron
Stroke 27.9 mm (1.100 in.)
Piston type Aluminum
Piston diameter 51.95 0.01 mm (2.0453 0.004 in.)
Ring end gap
Top ring 0.150.3 mm (0.00590.0118 in.)
Middle ring 0.150.3 mm (0.00590.0118 in.)
Bottom ring 0.10.35 mm (0.00390.014 in.)
Reed stand open (maximum) 0.25 mm (0.01 in.)
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.
Page 1A-4 90-8M0047659 JULY 2010

Specifications
Fuel System Specifications

Mechanical Fuel Pump Specifications
Mechanical fuel pump pressure at idle1.
Normal 13.720.5 kPa (23 psi)
Minimum 6.8 kPa (1 psi)
Mechanical fuel pump pressure at WOT1.
Maximum 68.5 kPa (10 psi)

Fuel pressure 751.5 6.9 kPa (109 1 psi)
Air pressure 655.0 6.9 kPa (95 1 psi)
Fuel/air differential 96.5 2.1 kPa (14 0.3 psi)
Highpressure fuel pump amperage draw 1014 amps
Lowpressure fuel pump amperage draw 12 amps
Lowpressure fuel pump output 137.9206.8 kPa (2030 psi)
Fuel pump ohm resistance 1.01.8
Fuel injector ohm resistance 1.8 0.1
Direct injector ohm resistance 1.3 0.3
Installation Specifications
a
a - Minimum transom opening
a b
b - Engine centerline for dual engine 66.0 cm
(26 in.)
18552
Minimum Transom Opening

Single engine 84.8 cm (333/8 in.)
Dual engine 151.8 cm (593/4 in.)
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)
90-8M0047659 JULY 2010 Page 1A-5

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.)
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 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 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.)
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.
Page 1A-6 90-8M0047659 JULY 2010

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.)
Gear Housing Specifications

Model 75/90 Gear Housing Specifications
Gear ratio 2.33:1
Gearcase capacity 665 ml (22.5 fl oz)
Lubricant type Premium Gear Lubricant
Forward gear number of teeth 28 spiral/bevel
Pinion gear number of teeth 12 spiral/bevel
Pinion height 0.64 mm (0.025 in.)
Forward gear backlash 0.330.48 mm (0.0130.019 in.)
Water pressure at 625675 RPM (idle) 20.641.3 kPa (36 psi)
Water pressure at 50005750 RPM (wideopen throttle) 75.896.5 kPa (1114 psi)
Poppet valve opening pressure 48.362.1 kPa (79 psi)
Normal temperature and when poppet valves open 1. 1800 RPM
Leak test 6983 kPa (1012 psi) for 5 minutes
Model 115/115 Pro XS/125 Gear Housing Specifications

Gear ratio 2.07:1
Normal temperature and when poppet valves open1. 1800 RPM
1. After the poppet valve opens at approximately 1800 RPM, the engine temperature will drop to 2738 C (80100 F).
90-8M0047659 JULY 2010 Page 1A-7

Specifications
Power Trim Specifications

Power Trim Specifications S/N 1B417702 and Above
Trim up circuit pressure, minimum 19,300 kPa (2800 psi)
Tilt relief pressure (up) 3,7236,825 kPa (540990 psi)
Trim down circuit pressure 3,4805,860 kPa (505850 psi)
System fluid Power Trim and Steering Fluid or automatic transmission fluid (ATF) (Dexron III)
Power Trim Specifications S/N 0T8010001B417701

Trim up circuit pressure, minimum 18,202 kPa (2,640 psi)
Cooling Specifications
Thermostat
Water pressure
At 625 RPM (idle) 20.641.3 kPa (36 psi)
At 5750 RPM (WOT) 75.896.5 kPa (1114 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)
Propeller Information Charts

75 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
No. of Approx. Gross Boat Approx. Boat Propeller Part

Diameter Pitch Model Speed Range
Blades Wgt. Length Number
Up to 680.3 kg Up to 4.8 m 75.695 km/h
13.5 26 3 Laser II 4816996A46
(1500 lb) (16 ft) (4759 MPH)
Up to 816.4 kg Up to 5.2 m 67.586.9 km/h
13.5 24 3 Laser II 4816994A46
(1800 lb) (17 ft) (4254 MPH)
Up to 816.4 kg Up to 5.2 m 67.586.9 km/h
12.75 24 5 High Five 48815746A45
(1800 lb) (17 ft) (4254 MPH)
Black Max 589.6861.8 kg 4.85.2 m 64.382 km/h
12.5 23 3 4877350A45
Aluminum (13001900 lb) (1617 ft) (4052 MPH)
680.3952.5 kg 4.85.4 m 59.578.8 km/h
13.5 22 3 Laser II 4816992A46
(15002100 lb) (1618 ft) (3749 MPH)
Page 1A-8 90-8M0047659 JULY 2010

Specifications

680.3952.5 kg 4.85.4 m 59.578.8 km/h
13 22 5 High Five 48815944A46
(15002100 lb) (1618 ft) (3749 MPH)
680.3997.9 kg 4.85.4 m 56.375.6 km/h
13.75 21 4 Trophy 48825934A47
(15002200 lb) (1618 ft) (3547 MPH)
680.3997.9 kg 4.85.4 m 56.375.6 km/h
13.25 21 3 Laser II 48899006A46
(15002200 lb) (1618 ft) (3547 MPH)
Black Max 680.3997.9 kg 4.85.4 m 56.375.6 km/h
12.75 21 3 4877348A45
725.71134 kg 5.25.7 m 51.472.4 km/h
13.25 20 3 Laser II 4816990A46
(16002500 lb) (1719 ft) (3245 MPH)
725.71134 kg 5.25.7 m 51.472.4 km/h
12.75 20 5 High Five 48816612A46
(16002500 lb) (1719 ft) (3245 MPH)
816.41270 kg 5.26.09 m 46.667.5 km/h
13.75 19 4 Trophy 48825932A46
(18002800 lb) (1720 ft) (2942 MPH)
816.41270 kg 5.26.09 m 46.667.5 km/h
13.25 19 3 Laser II 48899004A46
(18002800 lb) (1720 ft) (2942 MPH)
Black Max 816.41270 kg 5.26.09 m 6.667.5 km/h
13 19 3 4877346A45
861.81406.1 kg 5.46.09 m 43.462.7 km/h
13 18 3 Vengeance 4816988A46
(19003100 lb) (1820 ft) (2739 MPH)
952.51587.5 kg 5.76.4 m 38.662.7 km/h
13.75 17 4 Trophy 48825930A46
(21003500 lb) (1921 ft) (2439 MPH)
952.51587.5 kg 5.76.4 m 38.659.5 km/h
13.13 17 3 Vengeance 48854356A46
(21003500 lb) (1921 ft) (2437 MPH)
Black Max 952.51587.5 kg 5.76.4 m 38.659.5 km/h
13.25 17 3 4877344A45
1043.21905 kg 6.096.7 m 33.754.7 km/h
13.13 16 3 Vengeance 4816986A46
(23004200 lb) (2022 ft) (21 34 MPH)
Black Max 1315.42358.6 kg 6.096.7 m 33.754.7 km/h
13.25 16 3 48854360A45
1451.42857.6 kg 6.47.0 m 28.949.8 km/h
13.25 15 3 Vengeance 48854354A46
(32006300 lb) (2123 ft) (1831 MPH)
Black Max 1451.42857.6 kg 6.47.0 m 28.949.8 km/h
13.75 15 3 4877342A45
1587.53311.2 kg 6.47.3 m 25.746.6 km/h
13.38 15 3 Vengeance 4817314A46
(35007300 lb) (2124 ft) (1629 MPH)
Black Max 1587.53311.2 kg 6.47.3 m 25.746.6 km/h
13.88 14 3 48854352A45
Black Max 1587.53311.2 kg 6.47.3 m 25.746.6 km/h
14 14 4 48899018A45
Black Max 1814.34309.1 kg 6.79.1 m 20.941.8 km/h
14 13 3 4877340A45
Black Max 1814.34309.1 kg 6.79.1 m 20.941.8 km/h
14 13 4 48899016A45
1637 km/h
14 12 3 Vengeance 2131.8 kg (4700 + lb) Workboat 4817312A46
(1023 MPH)
Black Max 1637 km/h
14 12 4 2131.8 kg (4700 + lb) Pontoon/work 48899014A45
Aluminum (1023 MPH)
Black Max 1.632.1 km/h
Aluminum (120 MPH)
90-8M0047659 JULY 2010 Page 1A-9

Specifications

Aluminum (120 MPH)
90 OptiMax

Up to 680.3 kg Up to 4.8 m 75.695 km/h
13.5 26 3 Laser II 4816996A46
(1500 lb) (16 ft) (4759 MPH)
Up to 816.4 kg Up to 5.2 m 67.586.9 km/h
13.5 24 3 Laser II 4816994A46
(1800 lb) (17 ft) (4254 MPH)
Up to 816.4 kg Up to 5.2 m 67.586.9 km/h
12.75 24 5 High Five 48815746A45
(1800 lb) (17 ft) (4254 MPH)
Black Max 589.6861.8 kg 4.85.2 m 64.382 km/h
12.5 23 3 4877350A45
680.3952.5 kg 4.85.4 m 59.578.8 km/h
13.5 22 3 Laser II 4816992A46
(15002100 lb) (1618 ft) (3749 MPH)
680.3952.5 kg 4.85.4 m 59.578.8 km/h
13 22 5 High Five 48815944A46
(15002100 lb) (1618 ft) (3749 MPH)
680.3997.9 kg 4.85.4 m 56.375.6 km/h
13.75 21 4 Trophy 48825934A47
(15002200 lb) (1618 ft) (3547 MPH)
680.3997.9 kg 4.85.4 m 56.375.6 km/h
13.25 21 3 Laser II 48899006A46
(15002200 lb) (1618 ft) (3547 MPH)
Black Max 680.3997.9 kg 4.85.4 m 56.375.6 km/h
12.75 21 3 4877348A45
725.71134 kg 5.25.7 m 51.472.4 km/h
13.25 20 3 Laser II 4816990A46
(16002500 lb) (1719 ft) (3245 MPH)
725.71134 kg 5.25.7 m 51.472.4 km/h
12.75 20 5 High Five 48816612A46
(16002500 lb) (1719 ft) (3245 MPH)
816.41270 kg 5.26.09 m 46.667.5 km/h
13.75 19 4 Trophy 48825932A46
(18002800 lb) (1720 ft) (2942 MPH)
816.41270 kg 5.26.09 m 46.667.5 km/h
13.25 19 3 Laser II 48899004A46
(18002800 lb) (1720 ft) (2942 MPH)
Black Max 816.41270 kg 5.26.09 m 6.667.5 km/h
13 19 3 4877346A45
861.81406.1 kg 5.46.09 m 43.462.7 km/h
13 18 3 Vengeance 4816988A46
(19003100 lb) (1820 ft) (2739 MPH)
952.51587.5 kg 5.76.4 m 38.662.7 km/h
13.75 17 4 Trophy 48825930A46
(21003500 lb) (1921 ft) (2439 MPH)
952.51587.5 kg 5.76.4 m 38.659.5 km/h
13.13 17 3 Vengeance 48854356A46
(21003500 lb) (1921 ft) (2437 MPH)
Black Max 952.51587.5 kg 5.76.4 m 38.659.5 km/h
13.25 17 3 4877344A45
1043.21905 kg 6.096.7 m 33.754.7 km/h
13.13 16 3 Vengeance 4816986A46
(23004200 lb) (2022 ft) (2134 MPH)
Page 1A-10 90-8M0047659 JULY 2010

Specifications

Black Max 1315.42358.6 kg 6.096.7 m 33.754.7 km/h
13.25 16 3 48854360A45
1451.42857.6 kg 6.47.0 m 28.949.8 km/h
13.25 15 3 Vengeance 48854354A46
(32006300 lb) (2123 ft) (1831 MPH)
Black Max 1451.42857.6 kg 6.47.0 m 28.949.8 km/h
13.75 15 3 4877342A45
1587.53311.2 kg 6.47.3 m 25.746.6 km/h
13.38 15 3 Vengeance 4817314A46
(35007300 lb) (2124 ft) (1629 MPH)
Black Max 1587.53311.2 kg 6.47.3 m 25.746.6 km/h
13.88 14 3 48854352A45
Black Max 1587.53311.2 kg 6.47.3 m 25.746.6 km/h
14 14 4 48899018A45
Black Max 1814.34309.1 kg 6.79.1 m 20.941.8 km/h
14 13 3 4877340A45
Black Max 1814.34309.1 kg 6.79.1 m 20.941.8 km/h
14 13 4 48899016A45
1637 km/h
(1023 MPH)
Black Max 1637 km/h
Aluminum (1023 MPH)
Aluminum (120 MPH)
Aluminum (120 MPH)
115 OptiMax

Up to 635 kg Up to 4.8 m 107.8114.2 km/h
13.5 26 3 Laser II 4816996A46
(1400 lb) (16 ft) (6771 MPH)
Up to 725.7 kg Up to 5.2 m 93.3106.2 km/h
13.5 24 3 Laser II 4816994A46
(1600 lb) (17 ft) (5866 MPH)
Up to 725.7 kg Up to 5.2 m 93.3106.2 km/h
12.75 24 5 High Five 48815746A45
(1600 lb) (17 ft) (5866 MPH)
Black Max 635771.1 kg 4.55.2 m 88.5101.3 km/h
12.5 23 3 4877350A45
680.3816.4 kg 4.55.2 m 59.596.5 km/h
13.5 22 3 Laser II 4816992A46
(15001800 lb) (1517 ft) (5360 MPH)
680.3816.4 kg 4.55.2 m 59.596.5 km/h
13 22 5 High Five 48815944A46
(15001800 lb) (1517 ft) (5360 MPH)
771.1861.8 kg 4.55.2 m 80.491.7 km/h
13.75 21 4 Trophy 48825934A47
(17001900 lb) (1517 ft) (5057 MPH)
771.1861.8 kg 4.55.2 m 80.491.7 km/h
13.25 21 3 Laser II 48899006A46
(17001900 lb) (1517 ft) (5057 MPH)
90-8M0047659 JULY 2010 Page 1A-11

Specifications

Black Max 771.1861.8 kg 4.55.2 m 80.491.7 km/h
12.75 21 3 4877348A45
816.4952.5 kg 4.85.4 m 75.686.9 km/h
13.25 20 3 Laser II 4816990A46
(18002100 lb) (1618 ft) (4754 MPH)
816.4952.5 kg 4.85.4 m 75.686.9 km/h
12.75 20 5 High Five 48816612A46
(18002100 lb) (1618 ft) (4754 MPH)
861.81043.2 kg 4.85.4 m 70.882 km/h
13.75 19 4 Trophy 48825932A46
(19002300 lb) (1618 ft) (4451 MPH)
861.81043.2 kg 4.85.4 m 70.882 km/h
13.25 19 3 Laser II 48899004A46
(19002300 lb) (1618 ft) (4451 MPH)
Black Max 861.81043.2 kg 4.85.4 m 70.882 km/h
13 19 3 4877346A45
907.11134 kg 4.85.4 m 65.978.8 km/h
13 18 3 Vengeance 4816988A46
(20002500 lb) (1618 ft) (4149 MPH)
997.71224.6 kg 5.25.7 m 61.174 km/h
13.75 17 4 Trophy 48825930A46
(22002700 lb) (1719 ft) (3846 MPH)
997.71224.6 kg 5.25.7 m 61.174 km/h
13.13 17 3 Vengeance 48854356A46
(22002700 lb) (1719 ft) (3846 MPH)
Black Max 997.71224.6 kg 5.25.7 m 61.174 km/h
13.25 17 3 4877344A45
1043.21360.7 kg 5.26.09 m 56.369.2 km/h
13.13 16 3 Vengeance 4816986A46
(23003000 lb) (1720 ft) (3543 MPH)
Black Max 1043.21360.7 kg 5.26.09 m 56.369.2 km/h
13.25 16 3 48854360A45
1179.31587.5 kg 5.46.4 m 49.864.3 km/h
13.25 15 3 Vengeance 48854354A46
(26003500 lb) (1821 ft) (3140 MPH)
Black Max 1179.31598.5 kg 5.46.4 m 49.864.3 km/h
13.75 15 3 4877342A45
12701814.3 kg 5.77.0 m 4559.5 km/h
13.38 15 3 Vengeance 4817314A46
(28004000 lb) (1923 ft) (2837 MPH)
Black Max 12701814.3 kg 5.77.0 m 4559.5 km/h
13.88 14 3 48854352A45
Black Max 12701814.3 kg 5.77.0 m 4559.5 km/h
14 14 4 48899018A45
Black Max 1496.82222.6 kg 6.097.3 m 38.653.1 km/h
14 13 3 4877340A45
Black Max 1496.82222.6 kg 6.097.3 m 38.653.1 km/h
14 13 4 48899016A45
1723.62812.2 kg 32.148.2 km/h
14 12 3 Vengeance 6.7 m (22 + ft) 4817312A46
(38006200 lb) (2030 MPH)
Black Max 1723.62812.2 kg 32.148.2 km/h
14 12 4 6.7 m (22 + ft) 48899014A45
Aluminum (38006200 lb) (2030 MPH)
14 11 3 1905 kg (4200 + lb) Pontoon/work 4877338A45
Aluminum (1727 MPH)
14 11 4 1905 kg (4200 + lb) Pontoon/work 48899012A45
Aluminum (1727 MPH)
1.632.1 km/h
(120 MPH)
14 10 3 2267.9 kg (5000 + lb) House/work 48854342A45
Aluminum (120 MPH)
Page 1A-12 90-8M0047659 JULY 2010

Specifications

14 10 4 2267.9 kg (5000 + lb) House/work 48899010A45
Aluminum (120 MPH)
115 Pro XS
No. of Approx. Boat Propeller Part

Diameter Pitch Model Approx. Gross Boat Wgt. Speed Range
Blades Length Number
Up to 5.2 m 82.1104.6 km/h
13.5 26 3 Laser II Up to 862 kg (1900 lb) 4816996A46
(17 ft) (5165 MPH)
Up to 5.5 m 72.493.3 km/h
13.5 24 3 Laser II Up to 997.9 kg (2200 lb) 4816994A46
(18 ft) (4558 MPH)
Up to 907.21224.7 kg 4.95.5 m 64.483.7 km/h
13.5 22 3 Laser II 4816992A46
(20002700 lb) (1618 ft) (4052 MPH)
997.91360.7 kg 4.95.8 m 61.278.9 km/h
13.75 21 4 Trophy 48825934A47
(22003000 lb) (1619 ft) (3849 MPH)
997.91360.7 kg 4.95.8 m 61.278.9 km/h
13.5 21 3 Laser II 4889900646
(22003000 lb) (1619 ft) (3849 MPH)
1088.61496.7 kg 5.25.8 m 57.974.0 km/h
13.25 20 3 Laser II 4816990A46
(24003300 lb) (1719 ft) (3646 MPH)
1179.31632.9 kg 5.25.8 m 53.169.2 km/h
13.75 19 4 Trophy 48825932A46
(26003600 lb) (1719 ft) (3343 MPH)
1179.31632.9 kg 5.25.8 m 53.169.2 km/h
13.25 19 3 Laser II 48899004A46
(26003600 lb) (1719 ft) (3343 MPH)
1270.11814.9 kg 5.56.1 m 49.964.4 km/h
13 18 3 Vengeance 4816988A46
(28004000 lb) (1820 ft) (3140 MPH)
1406.11995.8 kg 5.56.4 m 46.659.5 km/h
13.75 17 4 Trophy 48825930A46
(31004400 lb) (1821 ft) (2937 MPH)
1542.22222.6 kg 5.86.7 m 41.854.7 km/h
13.13 16 3 Vengeance 4816986A46
(34004900 lb) (1922 ft) (2634 MPH)
125 OptiMax

Up to 861.8 kg Up to 5.2 m 82.1104.6 km/h
13.5 26 3 Laser II 4816996A46
(1900 lb) (17 ft) (5165 MPH)
Up to 997.9 kg Up to 5.5 m 72.493.3 km/h
13.5 24 3 Laser II 4816994A46
(2200 lb) (18 ft) (4558 MPH)
680.3816.4 kg 4.95.5 m 64.383.7 km/h
13.5 22 3 Laser II 4816992A46
(20002700 lb) (1618 ft) (4052 MPH)
997.91360.7 kg 4.95.8 m 61.278.9 km/h
13.75 21 4 Trophy 48825934A47
(22003000 lb) (1619 ft) (3849 MPH)
90-8M0047659 JULY 2010 Page 1A-13

Specifications

997.91360.7 kg 4.95.8 m 61.278.9 km/h
13.25 21 3 Laser II 48899006A46
(22003000 lb) (1619 ft) (3849 MPH)
Black Max 997.91360.7 kg 4.95.8 m 61.278.9 km/h
12.75 21 3 4877348A45
1088.61496.8 kg 5.25.8 m 57.974 km/h
13.25 20 3 Laser II 4816990A46
(24003300 lb) (1719 ft) (3646 MPH)
1179.31632.9 kg 5.25.8 m 53.169.2 km/h
13.75 19 4 Trophy 48825932A46
(26003600 lb) (1719 ft) (3343 MPH)
1179.31632.9 kg 5.25.8 m 53.169.2 km/h
13.25 19 3 Laser II 48899004A46
(26003600 lb) (1719 ft) (3343 MPH)
Black Max 1179.31632.9 kg 5.25.8 m 53.169.2 km/h
13 19 3 4877346A45
1270.11814.4 kg 5.56.1 m 49.964.4 km/h
13 18 3 Vengeance 4816988A46
(28004000 lb) (1820 ft) (3140 MPH)
1406.11224.6 kg 5.56.4 m 46.759.5 km/h
13.75 17 4 Trophy 48825930A46
(31004400 lb) (1821 ft) (2937 MPH)
Black Max 1406.11224.6 kg 5.56.4 m 46.759.5 km/h
13.25 17 3 4877344A45
1542.22222.6 kg 5.86.7 m 41.854.7 km/h
13.13 16 3 Vengeance 4816986A46
(34004900 lb) (1922 ft) (2634 MPH)
Black Max 1542.22222.6 kg 5.86.7 m 41.854.7 km/h
13.25 16 3 48854360A45
1723.62494.7 kg 5.87.0 m 38.649.9 km/h
13.25 15 3 Vengeance 48854354A46
(38005500 lb) (1923 ft) (2431 MPH)
Black Max 1723.62494.7 kg 5.87.0 m 38.649.9 km/h
13.75 15 3 4877342A45
1950.42812.3 kg 6.47.6 m 35.446.7 km/h
13.38 14 3 Vengeance 4817314A46
(43006200 lb) (2125 ft) (2229 MPH)
Black Max 1950.42812.3 kg 6.47.6 m 35.446.7 km/h
13.88 14 3 48854352A45
Black Max 2131.83175.0 kg 6.77.9 m 32.243.5 km/h
14 13 3 4877340A45
2630.8 + kg 27.437.0 km/h
14 12 3 Vengeance Pontoon boat 4817312A46
(5800 + lb) (1723 MPH)
Black Max 3084.4 + kg 24.132.2 km/h
14 11 3 Pontoon/work 4877338A45
Aluminum (6800 + lb) (1520 MPH)
4082.3 + kg 1.628.9 km/h
14 10 3 Vengeance House/work 4817310A46
(9000 + lb) (118 MPH)
Page 1A-14 90-8M0047659 JULY 2010

Maintenance
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
90-8M0047659 JULY 2010 Page 1B-1

Maintenance
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)
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)
Lubricant, Sealant, Adhesives

Tube Ref No. Description Where Used Part No.
Swivel bracket, tilt support lever, tilt tube, steering cable grease
34 Special Lubricant 101 92-802865Q02
fitting
94 Anti-Corrosion Grease Propeller shaft 92-802867Q 1
Propeller shaft
95 2-4-C with Teflon Swivel bracket, tilt support lever, tilt tube, steering cable grease 92-802859A 1
fitting
Power Trim and Steering
114 Power trim reservoir 92-858074K01
Fluid
120 Corrosion Guard External metal surfaces 92-802878 55
Special Tools
Fuel Filter Removal/Installation Tool 91896661
Aids in the removal and installation of the fuel filter cap assembly.
24896
Flushing Device 9144357Q 2
Attaches to the water intakes; provides a fresh water connection when flushing the
cooling system or operating the engine
9192
Page 1B-2 90-8M0047659 JULY 2010

Maintenance
Selecting Accessories for Your Outboard

Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard.
Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard
operating system. Acquire and read the installation, operation, and maintenance manuals for all selected accessories.
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.
Manufacturer's Certificate Label

The certification label must be placed on each engine at the time of manufacture and must be replaced in the same location if
damaged or removed. Shown below is a typical certification label and is not representative of any one model. Label shown below
is not to scale.
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)
Inspection and Maintenance Schedule

Before Each Use
Check that lanyard stop switch stops the engine.
Visually inspect the fuel system for deterioration or leaks.
Check outboard for tightness on transom.
Check steering system for binding or loose components.
Visually check steering link rod fasteners for proper tightness. See Steering Link Rod Fasteners.
Check propeller blades for damage.
90-8M0047659 JULY 2010 Page 1B-3

Maintenance
After Each Use

Flush out the outboard cooling system if operating in salt or polluted water. See Flushing the Cooling System.
Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in saltwater.
Every 100 Hours of Use or Once Yearly, Whichever Occurs First

Lubricate all lubrication points. Lubricate more frequently when used in saltwater. See Lubrication Points.
Replace spark plugs at first 100 hours or first year. After that, inspect spark plugs every 100 hours or once yearly. Replace
spark plugs as needed. See Spark Plug Inspection and Replacement.
Replace fuel filter. See Fuel System.
Replace compressor air intake filter. See Compressor Air Intake Filter.
Inspect alternator belt. See Alternator Belt Inspection.
Check corrosion control anodes. Check more frequently when used in saltwater. See Corrosion Control Anodes.
Drain and replace gearcase lubricant. See Gearcase Lubrication.
Check power trim fluid. See Checking Power Trim Fluid.
Inspect battery. See Battery Inspection.
Check control cable adjustments.1.
Lubricate splines on the driveshaft and shift shaft.1.
Check tightness of bolts, nuts, and other fasteners.
Every 300 Hours of Use or Three Years

Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted).1.
Replace the inline oil filter that is located in the oil hose between the oil tank and the oil injection pump.1.
Before Periods of Storage

Refer to Storage procedure. See Storage section.
Flushing the Cooling System

Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will help
prevent a buildup of deposits from clogging the internal water passages.
Use a Mercury Precision or Quicksilver accessory (or equivalent) flushing attachment.
! 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
1. These items should be serviced by an authorized dealer.
Page 1B-4 90-8M0047659 JULY 2010

Maintenance
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.
Flushing the Cooling System (Design 2)

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 that exceeds 310 kPa (45 psi).
1. Unscrew the cover from the end of the hose adapter.
2. Attach a water hose to the hose adapter.
3. Turn on the water and flush the cooling system for three minutes minimum.
IMPORTANT: Do not run engine above idle speed when flushing.
90-8M0047659 JULY 2010 Page 1B-5

Maintenance
4. Turn off the water and remove the water hose from the hose adapter. Reinstall the cover into the hose adapter.
a b
a - Hose adapter
b - Sealing washer
c - Cover
c
22703
Top Cowl Removal and Installation

Removal
1. Unlock the rear latch by pushing lever up.
2. Lift rear of cowl and disengage front hook.
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.
Cleaning Care for Top and Bottom Cowls

IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches. Always wet the surface
before cleaning. Do not use detergents containing hydrochloric acid. Follow the cleaning and waxing procedure.
Cleaning and Waxing Procedure

1. Before washing, rinse the cowls with clean water to remove dirt and dust that may scratch the surface.
2. Wash the cowls with clean water and a mild nonabrasive soap. Use a soft clean cloth when washing.
3. Dry thoroughly with a soft clean cloth.
4. Wax the surface using a nonabrasive automotive polish (polish designed for clear coat finishes). Remove the applied wax by
hand using a clean soft cloth.
5. To remove minor scratches, use Mercury Marine Cowl Finishing Compound (92859026K 1).
Flywheel Cover Removal and Installation

Removal
Lift the cover off the three mounting pins.
Page 1B-6 90-8M0047659 JULY 2010

Maintenance
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
Side Panel Removal and Installation

Removal
Pull the side panel off the three mounting pins.
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.
90-8M0047659 JULY 2010 Page 1B-7

Maintenance
Fuel Line Inspection

Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If
any of these conditions are found, the fuel line or primer bulb must be replaced.
Fuel Filter Replacement

Removal
Use fuel filter tool 91896661, or the shaft of a screwdriver, between the lugs on the filter cap and unscrew the filter.
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.
Draining Water from the Fuel Filter Chamber

NOTE: If a sufficient amount of water has accumulated in the fuel filter chamber, the warning system will turn on. Draining the
water from the fuel filter chamber is required.
1. Pull the drain hose off the right side fitting. Hold open end of the hose over a container.
2. Loosen drain screw and drain the fuel filter chamber.
a - Drain hose
b - Right side fitting
c - Drain screw
b
a c
29595
3. Retighten drain screw and reattach hose.

IMPORTANT: Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until firm, forcing fuel into the
chamber.
Steering Link Rod Fasteners

IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head
bolt ("a" Part Number 10849838) and selflocking nylon insert locknuts ("c" & "d" Part Number 11826709113). These locknuts
must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage.
Page 1B-8 90-8M0047659 JULY 2010

Maintenance
! 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.
a a- Special washer head bolt (10849838)

b b- Flat washer (2)
c- Nylon insert locknut (11826709113)
d- Nylon insert locknut (11826709113)
c
27843
d
Description Nm lbin. lbft

Special washer head bolt 27 20
Nylon insert locknut "d" 27 20
Tighten until seats, then back off 1/4
Nylon insert locknut "c"
turn
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.
Serial number 1B417701 and

a b below
a - 5 amp fuse SmartCraft
5 20 circuit
20 20 b - 20 amp fuse Accessories
c - 20 amp fuse Ignition coil
d c circuit
d - 20 amp fuse Electric fuel
pump, PCM driver power,
oil pump circuit, fuel pump
circuit, and direct injectors
circuit
26686
90-8M0047659 JULY 2010 Page 1B-9

Maintenance
a b c d e f
26685
Serial number 1B417702 and above

a - 20 amp fuse Ignition coil circuit
b - 15 amp fuse Remote harness, main power relay, and cowl mounted trim switch
c - Spare 20 amp fuse
d - 20 amp fuse Electric fuel pump, PCM driver power, oil pump circuit, fuel pump circuit, and direct injectors circuit
e - 2 amp fuse Diagnostics circuit
f - 5 amp fuse SmartCraft circuit
Inline Oil Filter Replacement

The inline oil filter is located between the oil reservoir and the oil pump on the starboard side of the engine. The inline oil filter
must be replaced every 300 hours or 3 years, whichever comes first.
1. Cut the two cable ties securing the inline oil filter to the oil line.
2. Use a suitable container to capture the oil that will drain from the oil lines. Remove the oil filter from the oil lines.
3. Install the oil filter onto the oil lines with the direction arrow pointing towards the oil pump.
4. Secure the oil filter to the oil lines with two cable ties.
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.
Corrosion Control Anode

An anode protects against galvanic corrosion by sacrificing its metal instead of the outboard metals.
Page 1B-10 90-8M0047659 JULY 2010

Maintenance
The gearcase has two corrosion control anodes, one on each side. A third anode is on the bottom of the transom bracket assembly.
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.

Hex nuts 13.5 120
IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.
90-8M0047659 JULY 2010 Page 1B-11

Maintenance
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.
NOTICE - DTS & OptiMax Engines

DO NOT USE DEEP CYCLE BATTERIES!
DTS (Digital Throttle and Shift) applications and
OptiMax engines must use a marine starting
battery with 1000 MCA, 800 CCA, or 180 Ah. rating.
13.5Nm (120 lbs. in.)
DO NOT
USE WING
NUTS
IMPORTANT:
Battery cable size and length is critical. Refer to
engine installation manual for size requirements.
37-895387
Place decal on or near battery box for future service

reference. 5/16 and 3/8 hex nuts supplied for wing
nut replacement. Metric hex nuts not supplied.
3486
Propeller Replacement
IMPORTANT: Propellers used on this product require the Mercury Marine FloTorq III type hub or equivalent.
! WARNING
1. Shift outboard to neutral (N) position.
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
3. Straighten the bent tabs on the propeller nut retainer.
26900
Page 1B-12 90-8M0047659 JULY 2010

Maintenance
4. Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut.
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

95 2-4-C with Teflon Propeller shaft 92-802859A 1
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.

Propeller nut 75 55
9. Secure propeller nut by bending three of the tabs into the thrust hub grooves.
26945
90-8M0047659 JULY 2010 Page 1B-13

Maintenance
Spark Plug Inspection and Replacement

! WARNING
Damaged spark plug boots may emit sparks which can ignite fuel vapors under the engine cowl, resulting in serious injury or
death from a fire or explosion. To avoid damaging the spark plug boots, do not use any sharp object or metal tool to remove the
spark plug boots.
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
3. Set the spark plug gap to specification.
26947
Spark Plug
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.

Spark plug 27 20
Compressor Air Intake Filter

The filter should be changed every 100 hours of operation, or once a season. Never run the engine without the air filter.
Removal
1. Remove the flywheel cover from the engine.
2. Remove the side cover from the engine.
Page 1B-14 90-8M0047659 JULY 2010

Maintenance
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.
a a- Oil tank/air attenuator

b- Filter
c- Cover
b d- Screw (3)
8245

Screws 10 88.5
Alternator Belt Inspection

! WARNING
Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key
before adjusting tension or inspecting belts.
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.
90-8M0047659 JULY 2010 Page 1B-15

Maintenance
c. Signs of wear on edges or outer surfaces of belt.
29477
Lubrication Points
1. Lubricate the following with Quicksilver or Mercury Precision Lubricants AntiCorrosion Grease or 24C with Teflon.

95 2-4-C with Teflon Propeller shaft 92-802859A 1
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.

Swivel bracket, tilt support lever, tilt tube, steering cable
34 Special Lubricant 101 92-802865Q02
grease fitting
Swivel bracket, tilt support lever, tilt tube, steering cable
95 2-4-C with Teflon 92-802859A 1
grease fitting
Swivel bracket Lubricate through fitting.

Tilt support lever Lubricate through fitting.
a - Swivel bracket
b - Tilt support lever
a
b
27873
Tilt tube Lubricate through fitting.
29478
Page 1B-16 90-8M0047659 JULY 2010

Maintenance
Steering cable grease fitting (if equipped) Rotate steering wheel to fully retract the steering cable end into the outboard
tilt tube. Lubricate through fitting.
! 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
Checking Power Trim Fluid

1. Tilt outboard to the full up position and engage the tilt support lever.
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.

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.
90-8M0047659 JULY 2010 Page 1B-17

Maintenance
Examine the drained gearcase lubricant for metal particles. A small amount of metal particles indicates normal gear wear. An
excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an
authorized dealer.
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
Gearcase Lubricant Capacity

Gearcase lubricant capacity is approximately 666 ml (22.5 fl oz).
Gearcase Lubricant Recommendation

Mercury or Quicksilver Premium or High Performance Gear Lubricant.
Checking Lubricant Level and Filling Gearcase

1. Place outboard in a vertical operating position.
2. Remove the front vent plug and rear vent plug.
3. Remove fill/drain plug. Place lubricant tube into the fill/drain plug hole and add lubricant until it appears at the front vent hole.
At this time install the front vent plug and sealing washer.
a- Front vent plug

b- Front vent hole
c c- Rear vent hole
d- Rear vent plug
b a d e- Fill/drain plug
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).
Page 1B-18 90-8M0047659 JULY 2010

Maintenance
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 - Left side fitting

b - Drain screw
c - Drain hose
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.
Flushing Device 9144357Q 2
90-8M0047659 JULY 2010 Page 1B-19

Maintenance
Protecting Internal Engine Components

NOTE: Make sure the fuel system has been prepared for storage. Refer to Fuel System, preceding.
IMPORTANT: Refer to Spark Plug Inspection and Replacement for correct procedure for removing spark plug leads.
1. Remove the spark plugs and add approximately 30 ml (1 oz) of engine oil into each spark plug hole.
2. Rotate the flywheel manually several times to distribute the oil in the cylinders.
3. Install the spark plugs.
Protecting External Outboard Components

Lubricate all outboard components listed in Inspection and Maintenance Schedule.
Touch up any paint nicks. See your dealer for touchup paint.
Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control
anodes).

120 Corrosion Guard External metal surfaces 92-802878 55
Gearcase
Drain and refill the gearcase lubricant (refer to Gearcase Lubrication).
Draining Hose Flush Attachment (if Equipped)

If the outboard is stored in freezing temperatures, the hose and flush attachment should be drained of water. Refer to Flushing
the Cooling System - Models with Accessory Flush Hose Attachment.
Positioning Outboard for Storage

Store outboard in an upright (vertical) position to allow water to drain out of the outboard.
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.
Page 1B-20 90-8M0047659 JULY 2010

General 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
90-8M0047659 JULY 2010 Page 1C-1

General Information
Special Tools
24896
Cylinder Leakage Tester SnapOn EEPV309A
Aids in checking cylinder leakdown.
11604
Serial Number Location

The serial number is located on the starboard side of the swivel bracket.
b
Serial Number
a xxxxxxxx a- Serial number

xxxx
xxxxxxxx b- Model year
Max RPM XXX
c c- Model designation
HPXX KW XX
LBXX KG XX d- Year manufactured
Mercury Marine
Brunswick Corp e- Certified Europe Insignia (as applicable)
Fond du Lac, Wi 52935
Assembled in the USA
from US and foreign
components
e xx d
21552
Page 1C-2 90-8M0047659 JULY 2010

General Information
Notes:
90-8M0047659 JULY 2010 Page 1C-3

General Information
Powerhead Starboard View (S/N 1B417702 and Above)

9 10 12
8 11
15
13 16
14
5 17
4
18
3 2
1
25 24 23 22 21 20 19 26704
Page 1C-4 90-8M0047659 JULY 2010

General Information
1- Telltale (water outlet from fuel rail) 14 - Propulsion control module
2- Start solenoid 15 - Oil tank
3- Engine flush hose 16 - Oil pump
4- Cylinder block water pressure hose 17 - Oil tank float sensor connector
5- #2 ignition coil 18 - Engine flush hose
6- Fuses (3 20 amp) (1 15 amp) 19 - Fuel delivery hose
7- Air compressor temperature sensor 20 - Battery positive and negative cables
8- Air compressor 21 - Trim down relay
9- Crankshaft position/engine speed sensor 22 - Cowl tilt switch connector
10 - Accessory belt tensioner pulley 23 - Trim up relay
11 - Air compressor inlet hose 24 - Main power relay
12 - Air compressor filter 25 - Battery power post
13 - Fuses (1 2 amp) (1 5 amp)
90-8M0047659 JULY 2010 Page 1C-5

General Information
Powerhead Induction Manifold View (S/N 1B417702 and Above)
3
5
2
6
1 7
26737
Page 1C-6 90-8M0047659 JULY 2010

General Information
1- Oil filter 5- Throttle body
2- Throttle position sensor 6- Manifold air temperature sensor
3- Throttle cables 7- Shift position switch
4- MAP sensor 8- Trim motor connectors
90-8M0047659 JULY 2010 Page 1C-7

General Information
Powerhead Port View (S/N 1B417702 and Above)
5 6 7 8 9 10 11
12
19
13
14
15
16
3
2
17
1
18
22 21 20
26707
Page 1C-8 90-8M0047659 JULY 2010

General Information
1- Vapor separator vent hose 12 - Lowpressure fuel test port
2- Fuel inlet hose to pulse fuel pump 13 - Vapor separator drain screw (tank)
3- Vapor separator drain screw (filter) 14 - Excess fuel return to vapor separator
4- Throttle cables 15 - SmartCraft connector
5- Water sensor connector 16 - Diagnostic connector
6- Pulse fuel pump 17 - Engine harness connector
7- Fuel/water separator filter 18 - Muffler for excess air return to driveshaft housing
8- Vapor separator vent hose 19 - Fuel/water sensor
9- 2 pin terminal connector for alternator 20 - Vapor separator drain hose
10 - Output terminal of alternator 21 - Throttle cable anchor point
11 - Fuel hose to fuel rail 22 - Shift cable anchor point
90-8M0047659 JULY 2010 Page 1C-9

General Information
Powerhead Aft View (S/N 1B417702 and Above)
12
11 13
14
15
10
9
16
8
17
18
7
19
6
20
3 21
2
22
26717
Page 1C-10 90-8M0047659 JULY 2010

General Information
1- Muffler for excess air return to driveshaft housing
2- Engine flush hose
3- Diagnostic connector
4- SmartCraft harness connector
5- Excess fuel return to vapor separator
6- Electric fuel pump connector
7- Alternator output cable (100 amp fuse)
8- Lowpressure fuel test port
9- Air pressure regulator
10 - Fuel pressure regulator
11 - Highpressure fuel delivery hose
12 - Water out from air compressor
13 - Air hose from air compressor
14 - Fuses (3 20 amp) (1 15 amp)
15 - #1 ignition coil
16 - Cylinder block temperature sensor connector
17 - Fuel pressure test valve
18 - #2 fuel injector
19 - Air pressure test valve
20 - Cylinder block water pressure hose
21 - Cowl tilt switch connector
22 - Telltale hose
90-8M0047659 JULY 2010 Page 1C-11

General Information
Powerhead Top View (S/N 1B417702 and Above)
10
11
4 12
13
14
15
3
2 16
1 26719
Page 1C-12 90-8M0047659 JULY 2010

General Information
1- Engine flush hose 9- Accessory belt tensioner pulley
2- Excess fuel return to vapor separator 10 - Water out from air compressor
3- Lowpressure fuel test port 11 - Air hose from air compressor
4- Highpressure fuel delivery hose 12 - Termination resistor
5- Vapor separator vent hose 13 - Fuses (3 20 amp) (1 15 amp)
6- Alternator 14 - Water delivery hose air compressor
7- Oil tank vent 15 - Cylinder block temperature sensor connector
8- Air compressor 16 - Fuel pressure regulator
90-8M0047659 JULY 2010 Page 1C-13

General Information
Powerhead Front View (S/N 1B417701 and Below)
15 1
14 2
13
12
3
11
10
9
5
4
32228
8
Page 1C-14 90-8M0047659 JULY 2010

General Information
1- MAP sensor 9- Trim pump bullet connectors
2- Air plenum 10 - Throttle body assembly
3- Pulse fuel pump 11 - Starter motor
4- SmartCraft connector 12 - Starter solenoid
5- Air temperature sensor connector 13 - Air compressor temperature sensor connector
6- Air temperature sensor 14 - Air compressor temperature sensor
7- MAP sensor connector 15 - Air compressor air inlet
8- Cowl tilt switch connectors
90-8M0047659 JULY 2010 Page 1C-15

General Information
Powerhead Starboard View (S/N 1B417701 and Below)

25
28
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
Page 1C-16 90-8M0047659 JULY 2010

General Information
1- MAP sensor 15 - Main power relay
2- Throttle body assembly 16 - Start solenoid
3- Air temperature sensor 17 - Propulsion control module
4- Oil filter 18 - Positive battery cable
5- Trim motor connectors 19 - #3 ignition coil
6- Cowl tilt switch connector 20 - #2 ignition coil
7- Neutral switch connectors 21 - #1 ignition coil
8- Negative battery cable 22 - Fuses (3 20 amp) (1 5 amp)
9- Throttle position sensor 23 - Air hose from air compressor
10 - Starter motor 24 - Air compressor temperature sensor
11 - Starter solenoid 25 - Telltale (water outlet from air compressor)
12 - Oil pump 26 - 100 amp fuse (alternator)
13 - Trim down relay 27 - Diagnostic terminal connector
14 - Trim up relay 28 - Crankshaft position/engine speed sensor
90-8M0047659 JULY 2010 Page 1C-17

General Information
Powerhead Port View (S/N 1B417701 and Below)
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
Page 1C-18 90-8M0047659 JULY 2010

General Information
1- Air plenum 15 - Vapor separator
2- Throttle cables 16 - Vapor separator drain fittings
3- Fuel/water separator filter 17 - Vapor separator drain hose
4- Vapor separator vent hose 18 - Water sensor connector
5- Alternator 2 pin connector 19 - Throttle cable anchor point
6- Output terminal of alternator 20 - Shift cable anchor point
7- Fuel out to fuel rail 21 - Engine harness connector
8- Highpressure electric fuel pump 22 - SmartCraft connector
9- Electric fuel pump connector 23 - Pulse fuel pump vacuum hose
10 - Lowpressure fuel test port 24 - Fuel/water sensor
11 - Excess fuel return to vapor separator 25 - Pulse fuel pump outlet hose
12 - Muffler for excess air return to driveshaft housing 26 - Pulse fuel pump
13 - Vapor separator drain screw 27 - Wideopen throttle stop screw
14 - Lowpressure electric fuel pump 28 - Fuel inlet hose to pulse fuel pump
90-8M0047659 JULY 2010 Page 1C-19

General Information
Powerhead Top View (S/N 1B417701 and Below)
12 2
1
11
10
4
9
6
11238
Page 1C-20 90-8M0047659 JULY 2010

General Information
1- Air compressor 7- Throttle plate adjustment screw
2- Fuel out to fuel rail 8- Starter motor
3- 60 amp alternator 9- Accessory belt tensioner pulley
4- Fuel/water separator filter 10 - Air compressor inlet nozzle
5- MAP sensor 11 - Air compressor water outlet to telltale
6- Throttle body assembly 12 - Air hose to fuel rail
90-8M0047659 JULY 2010 Page 1C-21

General Information
Powerhead Aft View (S/N 1B417701 and Below)
1 12
11
13
14
22
10
15
2 9
21
3
16
8
17
20
7
18
4
12
6
19
5 11242
Page 1C-22 90-8M0047659 JULY 2010

General Information
1- Highpressure fuel hose 12 - Water out from air compressor (telltale)
2- Electric fuel pump connector 13 - Air hose to fuel rail
3- Lowpressure fuel test port 14 - #1 fuel injector
4- Excess fuel return to vapor separator 15 - Fuel rail
5- Muffler for excess air return to driveshaft housing 16 - #2 fuel injector
6- Fuel pressure test valve 17 - Air pressure test valve
7- Air regulator 18 - #3 fuel injector
8- Fuel regulator 19 - Cowl tilt switch connector
9- Thermostat 20 - #3 ignition coil
10 - Water inlet hose to air compressor 21 - #2 ignition coil
11 - Temperature sensor 22 - #1 ignition coil
Conditions Affecting Performance

Weather
It is a known fact that weather conditions exert a profound effect on the power output of internal combustion engines. Established
horsepower ratings refer to the power the engine will produce at its rated RPM under a specific combination of weather conditions.
Corporations internationally have settled on adoption of International Standards Organization (ISO) engine test standards, as set
forth in ISO 3046 standardizing the computation of horsepower from data obtained on the dynamometer. All values are corrected
to the power the engine will produce at sea level, at 30% relative humidity, at 25 C (77 F) temperature, and a barometric pressure
of 29.61 inches of mercury.
Summer conditions of high temperature, low barometric pressure, and high humidity all combine to reduce the engine power. This,
in turn, is reflected in decreased boat speeds as much as 3 to 5 km/h (2 to 3 MPH) in some cases. Nothing will regain this speed
for the boater but cooler, dry weather.
Pointing out the consequences of weather effects, an engine running on a hot, humid day may encounter a loss of as much as
14% of the horsepower it would produce on a dry, brisk day. The horsepower that any internal combustion engine produces,
depends upon the density of the air that it consumes. The density of air is dependent upon the ambient air temperature, the
barometric pressure, and the humidity (water vapor) content.
Accompanying the effects of weather inspired loss of power is a second, but more subtle loss. Consider a boat rigged during
cooler, less humid weather with a propeller that allowed the engine to turn within its recommended RPM range at full throttle.
Higher temperatures with high humidity weather will consequently decrease the available horsepower. The propeller, in effect, is
too large for the atmospheric conditions and the engine operates at less than its recommended RPM.
The engine rated horsepower is a direct relation to the engines' RPM. An engine with too large a propeller will have a further loss
of horsepower and subsequent decrease in boat speed. This secondary loss of RPM and boat speed can be regained by switching
to a smaller pitch propeller that allows the engine to run at recommended RPM.
For boaters to realize optimum engine performance under changing weather conditions, it is essential the engine has the proper
propeller to allow it to operate at, or near, the top end of the recommended maximum RPM range at wideopen throttle with a
normal boat load. Not only does this allow the engine to develop full power, but equally important, the engine will be operating in
an RPM range that discourages damaging detonation. This enhances overall reliability and durability of the engine.
Weight Distribution (Passengers and Gear) Inside the Boat

Shifting weight to rear (stern):
Generally increases speed and engine RPM
Causes bow to bounce in choppy water
Increases danger of following wave splashing into the boat when coming off plane
At extremes, can cause the boat to porpoise
Shifting weight to front (bow):
Improves ease of planing
Improves rough water ride
At extremes, can cause the boat to veer back and forth (bow steer)
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.
90-8M0047659 JULY 2010 Page 1C-23

General Information
Rocker: The reverse of hook and much less common. Rocker exists if bottom is convex in fore and aft direction when viewed
from the side, and boat has strong tendency to porpoise.
Surface roughness: Moss, barnacles, etc., on boat or corrosion of outboard's gear housing increase skin friction and cause
speed loss. Clean surfaces when necessary.
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
Following Complete Submersion

Saltwater Submersion (Special Instructions)
Due to the corrosive effect of saltwater on internal engine components, complete disassembly of the engine is necessary before
any attempt is made to start the engine.
Engine Submerged While Running (Special Instructions)

When an engine is submerged while running, the possibility of internal engine damage is greatly increased. After the engine is
recovered, remove the spark plugs. If the engine fails to turn over freely when turning the flywheel, the possibility of internal damage
(bent connecting rod and/or bent crankshaft) exists. The powerhead must be disassembled for inspection.
Freshwater Submersion (Special Instructions)

IMPORTANT: Operate the engine within two hours after recovery, or serious internal damage may occur. If unable to start the
engine in this period, disassemble the engine and clean all parts. Apply oil as soon as possible.
If sand has entered the air intake on the engine, do not attempt to start the engine. Disassemble and clean all internal engine
components.
1. Recover the engine from the water as quickly as possible.
2. Remove the cowl.
3. Clean the exterior of the outboard with fresh water.
4. Dry all wiring and electrical components using compressed air.
5. Drain water from the fuel system as follows:
a. Disconnect the remote fuel hose from the engine.
b. Remove the drain plugs from the vapor separator and drain the fuel/water. Install the plugs after draining.
c. Remove the fuel hose from the bottom of the fuel rail and drain the fuel into an appropriate container. Install the fuel
hose.
d. Remove the water separating fuel filter and empty the contents.
6. Drain water from the air compressor system as follows:
a. Dry or replace the air filter for the compressor.
b. Remove the air outlet hose for the air compressor and drain water from the compressor and hose. Install the hose.
c. Remove the air hose from the bottom of the port side fuel rail and drain the water. Install the hose.
Page 1C-24 90-8M0047659 JULY 2010

General Information
7. Drain water from the engine as follows:
a. Tilt the outboard up and allow the water to drain from the crankcase area into the air plenum. Remove the manifold air
temperature sensor and allow the water to drain from the plenum.
b. Remove the spark plugs from the engine.
c. Rotate the flywheel manually to blow out any water from the cylinders.
d. Add approximately 30 ml (1 oz.) of engine oil into each spark plug hole. Rotate the flywheel manually several times to
distribute the oil. Install the spark plugs.
8. Drain water from the oil injection system as follows:
a. Remove the black remote oil hose without the blue stripe from the pulse fitting on the side of the cylinder block.
b. Drain any water from the hose and reconnect.
c. If water was present in the hose, check for water in the remote oil tank. Drain the remote oil tank if water is present.
9. Disassemble the engine starter motor and dry the components.
10. Prime the oil injection pump as follows:
a. Fill the engine fuel system with fuel. Connect the fuel hose and squeeze the primer bulb until firm.
b. Turn the ignition key switch to the "ON" position.
OFF
ON
START
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 and Oil

Fuel Recommendations
IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper
gasoline is considered misuse of the engine, and damage caused thereby will not be covered under the limited warranty.
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.
90-8M0047659 JULY 2010 Page 1C-25

General Information
Using Reformulated (Oxygenated) Gasolines (USA Only)

This type of gasoline is required in certain areas of the USA. The 2 types of oxygenates used in these fuels are alcohol (ethanol)
or ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasolines Containing
Alcohol.
These reformulated gasolines are acceptable for use in your Mercury Marine engine.
Gasolines Containing Alcohol

If the gasoline in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), you should be aware of certain
adverse effects that can occur. These adverse effects are more severe with methanol. Increasing the percentage of alcohol in the
fuel can also worsen these adverse effects.
Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air, resulting in a
separation of the water/alcohol from the gasoline in the fuel tank.
The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not
know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on
the boat's fuel system components (fuel tanks, fuel lines, and fittings). Be aware that gasolines containing alcohol may cause
increased:
Corrosion of metal parts
Deterioration of rubber or plastic parts
Fuel permeation through rubber fuel lines
Starting and operating difficulties
! 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.
Avoiding Fuel Flow Restriction

IMPORTANT: Adding components to the fuel supply system (filters, valves, fittings, etc.) may restrict the fuel flow. This may cause
engine stalling at low speed, and/or a lean fuel condition at high RPM that could cause engine damage.
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.
Page 1C-26 90-8M0047659 JULY 2010

General Information
Filling Oil Injection System

1. Place the outboard in a vertical operating position. Remove the cowl cap.
29462
2. Remove the oil filler cap.
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.
a - First ball marker

b - Second ball marker
a
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.
Capacity Fluid Type

Oil tank 4.72 liters (5 US qt) OptiMax/DFI 2Cycle Engine Oil
29465
5. Install oil filler cap and retighten. Reinstall the cowl cap.
29466
90-8M0047659 JULY 2010 Page 1C-27

General Information
Filling Fuel Tank

! WARNING
Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. Always stop the engine and
do not smoke or allow open flames or sparks in the area while filling fuel tanks.
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.
Fuel Filter Replacement

Removal
Use fuel filter tool 91896661, or the shaft of a screwdriver, between the lugs on the filter cap and unscrew the filter.
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.
Draining Water from the Fuel Filter Chamber

NOTE: If a sufficient amount of water has accumulated in the fuel filter chamber, the warning system will turn on. Draining the
water from the fuel filter chamber is required.
1. Pull the drain hose off the right side fitting. Hold open end of the hose over a container.
2. Loosen drain screw and drain the fuel filter chamber.
a - Drain hose
b - Right side fitting
c - Drain screw
b
a c
29595
3. Retighten drain screw and reattach hose.

IMPORTANT: Visually inspect for fuel leakage from the drain screw by squeezing the primer bulb until firm, forcing fuel into the
chamber.
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General Information
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 - Horn inside remote control

b - Horn connected to ignition key switch
a
27755
Warning Horn Signals

When the key switch is turned to the "ON" position, the horn will turn on for a moment as a test to show the horn is working.
The warning horn will emit either a continuous beep or intermittent short beeps. This will alert the operator and help identify the
following listed situations. For visual display of the specific engine functions and for additional engine data, refer to SmartCraft
Product information, following.
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.
Engine Guardian System

The Engine Guardian System monitors the critical sensors on the engine for any early indications of problems. The system will
respond to a problem by emitting a continuous beep and/or reducing engine power in order to provide engine protection.
If Guardian System has been activated, reduce throttle speed. The horn will turn off when throttle speed is within the allowable
limit. Consult your dealer for assistance.
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.
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General Information
Power Trim and Tilt

Your outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by
pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down. Moving the outboard
further away from the boat transom is called trimming out or up. The term trim generally refers to the adjustment of the outboard
within the first 20 range of travel. This is the range used while operating your boat on plane. The term tilt is generally used when
referring to adjusting the outboard further up out of the water. With the engine turned off, the outboard can be tilted out of the
water. At low idle speed, the outboard can also be tilted up past the trim range to permit, for example, shallow water operation.
a
a - Trim switch
b - Tilt range of travel
c - Trim range of travel
b
c 27761
Power Trim Operation

NOTE: When traveling at slow speeds, a slight drop in engine RPM may be noticed on occasion when engaging power trim. This
condition is normal and has no adverse affect on the outboard.
With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of
the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an improvement
in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control
hazards.
The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque
results from the outboard being trimmed so that the propeller shaft is not parallel to the water surface.
! 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.
Consider the following lists carefully.

1. Trimming in or down can:
Lower the bow.
Result in quicker planing off, especially with a heavy load or a stern heavy boat.
Generally improve the ride in choppy water.
Increase steering torque or pull to the right (with the normal righthand rotation propeller).
In excess, can lower the bow of some boats to a point where they begin to plow with their bow in the water while on
plane. This can result in an unexpected turn in either direction (called bow steering or oversteering) if any turn is
attempted, or if a significant wave is encountered.
! 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.
Page 1C-30 90-8M0047659 JULY 2010

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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.
a - Tilt support lever

b - Knob
a
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
Shallow Water Operation

When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom.
1. Reduce engine speed below 2000 RPM.
2. Tilt outboard up. Make sure all the water intake holes stay submerged at all times.
3. Operate the engine at slow speed only. If engine speed exceeds 2000 RPM, the outboard will automatically return down to
the maximum trim range.
Auxiliary Tilt Switch

The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system.
a - Auxiliary tilt switch
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.
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General Information
5. Check and record compression of each cylinder. The highest and lowest reading recorded should not differ by more than
15%. A reading below 827.4 kPa (120 psi) might indicate a total engine wear problem. The following chart, is not a
representation of compression values specific to the engine that is actually tested. It is only an example.
Compression Test Differences

Condition Maximum Reading Minimum Reading
Good 1241 kPa (180 psi) 1062 kPa (154 psi)
Bad 1172 kPa (170 psi) 972.2 kPa (141 psi)
6. To find the maximum allowable minimum compression reading difference, use this formula; highest compression reading x
0.85 = the lowest allowable difference. 1241 kPa x 0.85 = 1054.85 kPa (180 x 0.85 = 153 psi).
7. Compression check is important because an engine with low or uneven compression cannot be tuned successfully to give
peak performance. It is essential, therefore, that improper compression be corrected before proceeding with an engine
tuneup.
8. Cylinder scoring: If powerhead shows any indication of overheating, such as discolored or scorched paint, visually inspect
cylinders for scoring or other damage as outlined in Section 4 - Powerhead.
Cylinder Leakage Testing

IMPORTANT: Refer to the Master Specifications for the firing order of the engine.
NOTE: Cylinder leakage testing, along with compression testing, can help pinpoint the source of a mechanical failure by gauging
the amount of leakage in a cylinder. Refer to the manufacturer's tester instructions for proper testing procedures.
Cylinder Leakage Tester SnapOn EEPV309A
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.
Air Escaping from Possible Reason

Air induction Cylinder liner/piston damaged, carbon fouled rings, reed valve damaged
Exhaust system Cylinder liner/piston damaged, carbon fouled rings
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.
Page 1C-32 90-8M0047659 JULY 2010

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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.
Shipping of Hazardous Material (HazMat) and Engine/Components Containing

Hazardous Material
Outboard Service Bulletin 200807
There are a number of United States regulations regarding the shipment of hazardous material. These regulations apply not only
to shipments within the United States, but to import and export shipments as well. It is important to comply with all of these
regulations. This bulletin is intended to provide you with some basic information about some of these regulations, and provide you
with information about resources from which you can obtain additional information. It is also intended to draw your attention to the
importance of proper packaging, labeling, and shipping of hazardous material; as well as any engine or engine component that
contains hazardous material like gasoline or other fluids such as crankcase oil, gearcase oil, and hydraulic fluid. There are also
requirements for training personnel that deal with the shipment of hazardous material. This bulletin is intended to draw your
attention to some of the shipping regulations that we are aware of that might apply to your business, it is not a complete review
of all of the laws and regulations that apply to the shipment of hazardous materials. Please do not treat it as such.
NOTE: You, as the shipper of record, are responsible for classification, packaging, hazard communication, incident reporting,
handling, and transportation of hazardous materials.
90-8M0047659 JULY 2010 Page 1C-33

General Information
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).
Overview of Training Requirements

Current U.S. Department of Transportation (DOT) regulations require initial training (and recurrent training) of all employees who
perform work functions covered by the Hazardous Materials Regulations. Any employee who works in a shipping, receiving, or
material handling area; or who may be involved in preparing or transporting hazardous materials, is required to have training.
Hazardous materials transportation training is available from ShipMate, Inc. The training modules on CDROM or online contain
an interactive training program which satisfies the DOT requirement for general awareness, general safety, and HazMat security
training. A comprehensive exam is offered and Certificates of Completion are generated upon successful completion of the
program. The CDROM and online WebBased Training may be purchased from ShipMate, Inc. This also includes an electronic
version of the 49 CFR Hazardous Materials Regulations, the current Emergency Response Guidebook, and full access to
ShipMates technical staff to assist you in properly preparing hazardous materials for transport. ShipMate, Inc. may be reached
at 13103703600 or on the web at http://www.shipmate.com.
NOTE: The DOT training program does NOT include a test of any type and contains a lot of material which is not relevant (e.g.
cargo tanks). In addition, you would have to purchase the 49 CFR and the Emergency Response Guidebook separately. Further,
the DOT program provides no support technical or otherwise. For further information, view the DOT website at http://www.dot.gov.
Shipping of Complete Engines and Major Assemblies

Complete engines cannot be transported without going through additional preparation first. Electronic fuel injection (EFI) and direct
fuel injection (DFI) engines must have the fuel system drained of fuel, not run dry because of possible damage to electric fuel
pumps. Carbureted engines must be completely run dry and have stalled due to lack of fuel. All engines must have any remaining
fluids/oils drained (including engine and gearcase oil) and hydraulic fluids (including power trim fluid) and disconnected fluid pipes
that previously contained fluid must be sealed with leakproof caps that are positively retained. Major assemblies such as
gearcases, dressed powerheads, or other components containing any fluids must be also drained prior to shipping.
More Information on Hazardous Material

More information on hazardous material, regulations, packaging, training, etc. can be found by going to the ShipMate website:
http://www.shipmate.com or by calling or writing to:
ShipMate, Inc.
18436 Hawthorne Blvd., Suite 201
Torrance, CA 90504
USA
Telephone + 1 (310) 370-3600
Fax + 1 (310) 370-5700
E-mail: shipmate@shipmate.com
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.
Page 1C-34 90-8M0047659 JULY 2010

General Information
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.
Trim Tab Adjustment

Propeller steering torque will cause your boat to pull in one direction. This steering torque is a normal thing that results from your
outboard not being trimmed so the propeller shaft is parallel to the water surface. The trim tab can help compensate for this steering
torque in many cases and can be adjusted within limits to reduce any unequal steering effort.
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.
Engine BreakIn Procedure

IMPORTANT: Failure to follow the engine breakin procedures can result in poor performance throughout the life of the engine
and can cause engine damage. Always follow breakin procedures.
Gasoline/Oil BreakIn Mixture

NOTE: Do not use premixed gas and oil during breakin. Use straight gasoline during engine breakin and after engine breakin.
The engine breakin procedure for an OptiMax outboard is important to ensure proper performance and maximum life from the
engine. The following breakin procedure allows the internal engine parts to wearin evenly. Incorrect engine breakin can shorten
the engine life.
The engine automatically receives extra oil during the first hours of operation. For most boaters this extra oil mode will be complete
in about ten hours.
BreakIn Procedure
1. For the first hour of operation, allow the engine to warm up for 3060 seconds.
90-8M0047659 JULY 2010 Page 1C-35

General Information
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.
Page 1C-36 90-8M0047659 JULY 2010

Outboard Installation
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
90-8M0047659 JULY 2010 Page 1D-1

Installation Specifications
a
a - Minimum transom opening
a b
b - Engine centerline for dual engine 66.0 cm
(26 in.)
18552
Minimum Transom Opening

Single engine 84.8 cm (333/8 in.)
Dual engine 151.8 cm (593/4 in.)
Lubricants, Sealants, Adhesives

95 2-4-C with Teflon O-ring seal and entire cable end 92-802859A 1
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
Transom Drilling Fixture 9198234A2
Aids in engine installation by acting as a template for engine mounting holes.
5489
Stainless Steel Tilt Pin 1749930A 1
Limits the down trim angle of the power trim equipped engines, or aids in
determining the trim out angle on nonpower trim engines.
2749
Lifting the Outboard

! WARNING
Improperly supporting an engine during lifting can result in the engine falling, causing serious injury or death. Before lifting the
engine, verify that the lifting ring is threaded into the flywheel for a minimum of five turns and that the hoist has the correct lifting
capacity for the engine weight.
To lift the outboard:

1. Remove the cowl from the outboard.
Page 1D-2 90-8M0047659 JULY 2010

2. Thread the lifting eye into the flywheel hub for a minimum of five turns.
15363

3. Connect a hoist to the lifting eye.
4. Lift the outboard and place it on the boat transom.
Steering Cable Starboard Side Routed Cable

1. Lubricate Oring seal and entire cable end.
95
3724

95 2-4-C with Teflon O-ring seal and entire cable end 92-802859A 1
2. Insert steering cable into tilt tube.
3725
90-8M0047659 JULY 2010 Page 1D-3

3. Torque nut to specification.
3727

Nut 47.5 35
Steering Link Rod Fasteners

IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head
bolt ("a" Part Number 10849838) and selflocking nylon insert locknuts ("c" & "d" Part Number 11826709113). These locknuts
must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage.
! 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.
a a- Special washer head bolt (10849838)

b b- Flat washer (2)
c- Nylon insert locknut (11826709113)
d- Nylon insert locknut (11826709113)
c
27843
d

Special washer head bolt 27 20
Nylon insert locknut "d" 27 20
Tighten until seats, then back off 1/4
Nylon insert locknut "c"
turn
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.
Drilling Outboard Mounting Holes

IMPORTANT: Before drilling any mounting holes, carefully read Determining Recommended Outboard Mounting Height and install
the outboard to the nearest recommended mounting height.
Page 1D-4 90-8M0047659 JULY 2010

1. Mark four mounting holes on the transom using the transom drilling fixture.
b a - Drill guide holes

b - Transom drilling fixture
c - Transom centerline
c 2757
Transom Drilling Fixture 9198234A2

2. Drill four 13.5 mm (17/32 in.) mounting holes.
3973
3. Apply marine sealer to the shanks of the bolts, not the threads.
4. Fasten the outboard with the provided mounting hardware.
a- Flat washer (4)

b- 1/2 in. diameter bolt (4)
c- Shank of bolt
d- Flat washer (4)
e- Locknut (4)
a
b
d
c 3729
90-8M0047659 JULY 2010 Page 1D-5

Determining Recommended Outboard Mounting Height

63.5 cm
(25 in.)
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
a- The solid line is recommended to determine the outboard mounting height

b- The broken lines represent the extremes of known successful outboard mounting height dimensions
c- The line may be preferred to determine outboard mounting height dimension, if maximum speed is the only objective
d- The line may be preferred to determine outboard mounting height dimension for dual outboard installation
e- Outboard mounting height (height of outboard mounting brackets from bottom of boat transom). For heights over 56.0 cm
(22 in.), a propeller, that is designed for surfacing operation, is usually preferred.
f - Maximum boat speed (MPH) anticipated
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.
Increasing the mounting height will usually:

Reduce steering torque.
Increase top speed.
Increase boat stability.
Cause propeller to break loose during planing.
Fastening the Outboard to the Transom

Mounting Bolts
Outboard Transom Mounting Hardware Supplied with Outboard
Part Number Part Name Description
10677551 Transom bolt 1/220 x 4.50 in. long (2.25 in. thread)
Page 1D-6 90-8M0047659 JULY 2010

Outboard Transom Mounting Hardware Supplied with Outboard

1182671117 Nylon insert locknut 1/220
1228421 Washer Inner 0.516 in. ID x 1.50 in. OD
1254012 Washer Outer 0.53 in. ID x 0.87 in. OD
Available Transom Mounting Bolts

108M0028080 Transom bolt 1/220 x 7.50 in. long (2.75 in. thread)
108M0032860 Transom bolt 1/220 x 8.00 in. long (2.75 in. thread)
Checking Boat Transom Construction

IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm
(55 lbft) of torque without the boat transom yielding or cracking. If the boat transom yields or cracks under this torque, the
construction of the transom may not be adequate. The boat transom must be strengthened or the load carrying area increased.
a - Transom yielding under bolt torque

b - Transom cracking under bolt torque
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
Description Part Number

Large transom washer 67896392
Transom reinforcement plate 67896305
1. Apply marine sealer to shanks of bolts, not the threads.

2. Fasten the outboard with the correct mounting hardware. Tighten locknuts to the specified torque.
90-8M0047659 JULY 2010 Page 1D-7

NOTE: For more accurate torque, whenever possible turn/tighten the mounting locknuts rather than turning the mounting
bolts.
d a- 1/2 in. diameter outboard mounting bolt (4)

b- 7/8 in. flat washer (4)
c c- Nylon insert locknut (4)
a
d- 11/2 in. flat washer (4)
e- Marine sealer apply to the shank of the bolts,
not to the threads
e
b
c
d a
40952

Outboard mounting locknuts and bolts standard transom 75 55
Outboard mounting locknuts and bolts metal lift plates and setback brackets 122 90
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.
Page 1D-8 90-8M0047659 JULY 2010

4. Install the flush hose after removing the knockouts. Refer to Flush Hose Routing.
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
Flush Hose Routing

If desired, the flush hose can be routed outside the cowling as follows:
1. Using a needlenose pliers, break out the semicircular knockouts in the access cover and lower cover. Smooth the edges of
the knockout with sandpaper or a small knife.
2. Route the flush hose through this opening.
a - Knockout
a b - Flush hose
23642
90-8M0047659 JULY 2010 Page 1D-9

Remote Boat Harness

Route the remote boat harness through the grommet. Connect the remote harness to the 14 pin connector on the engine harness.
a
a - Remote 14 pin boat harness
23699
Battery Information
! WARNING
connections.

Hex nuts 13.5 120

13.5Nm (120 lbs. in.)
DO NOT
USE WING
NUTS
IMPORTANT:
37-895387

3486
Page 1D-10 90-8M0047659 JULY 2010

Battery Cable Connections

Single Outboard
a a - Red sleeve Positive (+)

b - Black sleeve Negative ()
c - Cranking battery
(+)
b c
(-) 15496
Dual Outboards
Connect a common ground cable (wire size same as engine battery cables) between negative () terminals on starting batteries.
a a- Red sleeve Positive (+)

b- Black sleeve Negative ()
c- Ground cable
d- Cranking battery
b
a (-)
d
b
c (-)
d
15497
SmartCraft Harness Connection

If SmartCraft gauges are being used with the outboard, route the SmartCraft wiring harness through the grommet and connect it
to the SmartCraft harness connector on the engine.
a - SmartCraft harness connector
23700
90-8M0047659 JULY 2010 Page 1D-11

Water Pressure Tube Connection

If a water connection to the engine is required for a water pressure gauge, make the connection as follows:
1. The water pressure tube is coiled and attached on the side of the engine. Cut the cable tie and route the water pressure tube
out through the grommet.
a - Water pressure tube
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
Fuel Hose Connection

Remote Fuel Hose Size
Minimum fuel hose inside diameter (ID) is 8 mm (5/16 in.) with separate fuel hose/fuel tank pickup for each engine.

Fasten the remote fuel hose to the fitting with a hose clamp.
a - Hose clamp
b - Remote fuel hose
a b
23709
Page 1D-12 90-8M0047659 JULY 2010

Shift Cable Installation

NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved
out of neutral.
Install cables into the remote control following the instructions provided with the remote control.
1. Position remote control into neutral.
26838
2. Shift outboard into neutral.

3. Measure the distance between pin and center of barrel pocket.
a a - Distance between pin and center of lower hole

b - Pin
c - Barrel pocket
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
90-8M0047659 JULY 2010 Page 1D-13

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.
Throttle Cable Installation

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
Page 1D-14 90-8M0047659 JULY 2010

Electrical, Fuel Hose, and Control Cables S/N 1B2270001B417701

Front Cover Assembly
Removal
Pull up the cowl and remove the cover from the bottom cowl.
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
4. Reinstall the cover and cowl seal.
a
a - Screw (2)
a b - Cover
7896
90-8M0047659 JULY 2010 Page 1D-15

Remote Wiring Harness

Route the remote 14 pin boat harness through the front clamp. Connect the remote harness to the 14 pin connector on the engine
harness.
a
a - 14 pin connector
b - Remote 14 pin boat harness
b
11042
Battery Information
! WARNING
connections.

Hex nuts 13.5 120

13.5Nm (120 lbs. in.)
DO NOT
USE WING
NUTS
IMPORTANT:
37-895387

3486
Page 1D-16 90-8M0047659 JULY 2010


Single Outboard

(+)
b c
(-) 15496
Dual Outboards

c- Ground cable
d- Cranking battery
b
a (-)
d
b
c (-)
d
15497

Fasten remote fuel hose to fitting with hose clamp.
Fuel Hose Size

Minimum fuel line inside diameter is 8 mm (5/16 in.) with separate fuel line/fuel tank pickup for each engine.
a - Fuel hose
b - Hose clamp
b
a
7907
90-8M0047659 JULY 2010 Page 1D-17


out of neutral.
26838


b - Pin
c - Barrel pocket
c
b
23720
F N R
b
a - Shift cable end
a
b - Cable barrel
23721
Page 1D-18 90-8M0047659 JULY 2010

b
a - Cable barrel
a c
b - Locknut
c - Flat washer
7736
cable end.

26838
2. Install throttle cable to the throttle arm with flat washer and locknut. Tighten locknut, then back off locknut 1/4 turn.
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
90-8M0047659 JULY 2010 Page 1D-19

Electrical, Fuel Hose, and Control Cables 0T8010001B226999

Front Cover Assembly
Removal
Pull up the cowl and remove the cover from the bottom cowl.
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
4. Reinstall the cover and cowl seal.
a
a - Screw (2)
a b - Cover
7896
Remote Wire Harness

1. Connect the remote wire harness to the engine harness connector.
2. Push the retainer over the ends of the connectors.
Page 1D-20 90-8M0047659 JULY 2010

3. Install the harness connection into the harness holder on the bottom cowl.
10392
Battery Information
! WARNING
connections.

Hex nuts 13.5 120

13.5Nm (120 lbs. in.)
DO NOT
USE WING
NUTS
IMPORTANT:
37-895387

3486
90-8M0047659 JULY 2010 Page 1D-21


Single Outboard

(+)
b c
(-) 15496
Dual Outboards

c- Ground cable
d- Cranking battery
b
a (-)
d
b
c (-)
d
15497

Fasten remote fuel hose to fitting with hose clamp.
Fuel Hose Size

Minimum fuel line inside diameter is 8 mm (5/16 in.) with separate fuel line/fuel tank pickup for each engine.
a - Fuel hose
b - Hose clamp
b
a
7907
Page 1D-22 90-8M0047659 JULY 2010

Water Pressure Tube Connection

Connect water pressure tube as follows:
a- Water pressure tubing

b- Water pressure tube
c- Plug
d- Coupler
e- Barb hose fitting
a
b c d
e
7735

out of neutral.
26838


b - Pin
c - Barrel pocket
c
b
23720
F N R
90-8M0047659 JULY 2010 Page 1D-23

b
a - Shift cable end
a
b - Cable barrel
23721
b
a - Cable barrel
a c
b - Locknut
c - Flat washer
7736
cable end.

26838
2. Install throttle cable to the throttle arm with flat washer and locknut. Tighten locknut, then back off locknut 1/4 turn.
4. Place cable barrel into retainer.
Page 1D-24 90-8M0047659 JULY 2010

a- Flat washer
b- Locknut
c- Barrel retainer
c d- Cable barrel
e- Cable latch
d
a b
e
15317
Filling the Fuel System

When starting an engine for the first time, or starting an engine that ran out of fuel or was drained of fuel, fill and prime the fuel
system.
To fill and prime the fuel system:
1. Squeeze the fuel line primer bulb until it feels firm.
2. Turn the key switch to the "ON" position for three seconds. This operates the electric fuel pump.
3. Turn the key switch back to the "OFF" position and squeeze the primer bulb again until it feels firm.
4. Turn the key switch to the "ON" position again for three seconds.
5. Continue this procedure until the fuel line primer bulb stays firm.
Filling Oil Injection System

1. Place the outboard in a vertical operating position. Remove the cowl cap.
2. Remove the oil filler cap.
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.
a - First ball marker

b - Second ball marker
a
b
29464
90-8M0047659 JULY 2010 Page 1D-25

4. Oil filler caps with a dipstick check the oil level on the dipstick. The first set of holes indicates 0.94 liter (1.0 US qt) low. The
second set of holes indicates 1.89 liter (2.0 US qt) low. The third set of holes indicates 2.83 liter (3.0 US qt) low.
a - Add 0.94 liter (1.0 US qt)

b - Add 1.89 liter (2.0 US qt)
a c - Add 2.83 liter (3.0 US qt)
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.
Capacity Fluid Type

Oil tank 4.72 liter (5.0 US qt) OptiMax/DFI 2Cycle Engine Oil
29465
6. Install the oil filler cap and retighten. Reinstall the cowl cap.
29466
Priming the Oil Injection Pump

Before starting the engine for the first time, prime the oil injection pump. Priming will remove any air that may be in the pump, oil
supply hose, or internal passages.
a - Oil injection pump

b - Oil supply hose
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:
Page 1D-26 90-8M0047659 JULY 2010

1. Fill the engine fuel tank with fuel.
NOTE: Use the primer bulb located in the fuel hose to the engine to draw fuel from the fuel tank to fill the engine fuel system.
2. Position the fuel hose primer so that the arrow on the side of the bulb is pointing up. Squeeze the fuel hose primer bulb until
it feels firm.
27348
3. Turn the ignition key switch to the "ON" position.
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
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

Propeller nut 75 55
90-8M0047659 JULY 2010 Page 1D-27

Trim In Pin
! WARNING
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.
a - Tilt pin (not included with engine)
2688
Stainless Steel Tilt Pin 1749930A 1
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.
Paddle Wheel Speed Sensor Installation (if Equipped)

Parts Provided
e
d
a i
b
c
i
h
ABCD
f 29269
j
g
a- Spare pin yoke

b- Wire retainer
c- Connector
d- Bracket
e- Paddle wheel
f- Flat washer (2)
g- #10 screw 19 mm (3/4 in.) (4)
h- Cable cap
i- #6 screw 12 mm (1/2 in.) (4)
j- Clamp (2)
Page 1D-28 90-8M0047659 JULY 2010

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.)
Transom Angle Requirements

Standard 13 to 20 transoms No special adjustment required.
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.
90-8M0047659 JULY 2010 Page 1D-29

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
Routing the Cable

Drilling Hole Through Transom (optional)
1. Select a transom location for the hole above the waterline that does not interfere with other cables and controls.
2. Drill a 15 mm (5/8 in.) diameter hole.
3. Route the cable through the drilled hole. Seal the transom hole with silicone (RTV) or a comparable marine sealer after the
cable has been routed through.
NOTE: The hole for the first clamp should be 25 mm (1 in.) above the paddle wheel. The hole for the second clamp should
be positioned halfway between the first clamp and the cap covering the transom hole drilled for the cable.
4. Using a 2.8 mm (7/64 in.) bit, drill holes for the clamps and cap approximately 13 mm (1/2 in.) deep.
5. Apply silicone sealer (RTV) or a comparable marine sealer to the screw threads, install the cable clamps and feed the cable
through the cable cap.
Without Drilling Hole Through Transom (optional)

Route the cable over the transom or through a drain hole that is above the waterline.
a- Splash well drain hole

a b- Cable cap
c- Cable clamp
b d- Paddle wheel assembly
e- Distance between first cable clamp and top of paddle
wheel 25.4 mm (1.0 in.)
c
e
d
29285
Installing and Removing the Paddle Wheel

Installation Slide the pins into the slots in the bracket and snap the tabs into place.
Removal Squeeze open (unlock) the tabs and pull on the paddle wheel.
a
a - Tabs
b - Pins
b 29288
Page 1D-30 90-8M0047659 JULY 2010

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
Template Paddle Wheel Speed Sensor
a a - Drill holes here

b - Align dotted line with the transom bottom edge and fold under
29291
90-8M0047659 JULY 2010 Page 1D-31

Notes:
Page 1D-32 90-8M0047659 JULY 2010

Ignition
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
90-8M0047659 JULY 2010 Page 2A-1

Ignition
Firing order 123
Air gap (S/N 0G5900000T178499) 5 mm (0.20 in.)

7 Loctite 271 Threadlocker TPS screws 92-809819
Loctite 567 PST Pipe
9 Air compressor head temperature sensor threads 92-809822
Sealant
Eyelet wiring terminals
25 Liquid Neoprene 92- 25711 3
All ring terminal connections
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
Extension Cable 84825003A1
Data link extension harness (3.05 m [10 ft.]) between the adapter harness and the
Digital Diagnostic Terminal or Computer Diagnostic System (CDS).
4012
Page 2A-2 90-8M0047659 JULY 2010

Ignition
Adapter Harness 84822560A13
Data link harness between engine and Computer Diagnostic System (CDS).
5826
DMT 2004 Digital Multimeter 91892647A01
Measures RPM on spark ignition (SI) engines, ohms, amperes, AC and DC

V Hz
H z TEMP
mA
A voltages; records maximums and minimums simultaneously, and accurately reads
in high RFI environments.
mV IG
OFF IP
TEMP
A mA COM V Hz
4516
Flywheel Puller 9173687A2
Removes the flywheel from the crankshaft.

7617
Flywheel Holding Tool 9152344
Holds and/or turns the flywheel while making engine repairs, also used to torque
the flywheel or the engine coupler.
4738
90-8M0047659 JULY 2010 Page 2A-3

Ignition
Electrical Components S/N 0T8010001B226999

8
9
10
25
61 11 51
54 14 52
64 63 62 1
53
7 60
13
6 12 19
16
13 59
20 18
58 17
12
25 7 15
27
2
25
26
15 22 25
24
3 5 23
17
13 21 37
29
6 31 32
4 35
6 12 36
30
43 28 13 32
17 33
39 38
44
45
34
46
48
47 57
40
56
55
42 50
41 49
56
1691
Page 2A-4 90-8M0047659 JULY 2010

Ignition

Torque
Ref. No. Qty. Description Nm lbin. lbft
1 1 Electrical plate
2 3 Ignition coil
3 3 Hightension lead
4 3 Spark plug (PZFR6H) 27 20
5 6 Screw (M6 x 30) 6.8 60
6 3 Clip
7 2 Screw (M6 x 12) 6.8 60
8 1 Pressure sensor
9 1 Clip
10 1 Fitting
11 1 Tubing
12 5 Screw (M6 x 14) 6.8 60
13 5 Washer
14 1 Cable assembly (braided)
15 2 Clip
16 1 PCM
17 8 Screw (M6 x 25) 4 35
18 3 Washer
19 3 Grommet
20 3 Bushing
21 3 Trim relay
22 3 Bracket
23 3 Grommet
24 3 Bushing
25 3 Pin
26 1 Spacer
27 1 Nut (M6) 10 88.5
28 1 Clip
29 1 Start solenoid
30 2 Grommet
31 2 Bushing
32 2 Nut (1032) (brass) 0.9 8
33 1 Cap nut
34 1 Cable
35 2 Lockwasher
36 2 Nut (0.31218) (stainless steel) 5.5 50
37 1 Cable
38 1 Boot (yellow)
39 1 Trim harness
40 1 Fuse harness (with 100 amp fuse)
90-8M0047659 JULY 2010 Page 2A-5

Ignition
Torque
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

25 Liquid Neoprene Eyelet wiring terminals 92- 25711 3
Page 2A-6 90-8M0047659 JULY 2010

Ignition

8
9
10
25
61 11 51
54 14 52
64 63 62 1
53
7 60
13
6 12 19
16
13 59
20 18
58 17
12
25 7 15
27
2
25
26
15 22 25
24
3 5 23
17
13 21 37
29
6 31 32
4 35
6 12 36
30
43 28 13 32
17 33
39 38
44
45
34
46
48
47 57
40
56
55
42 50
41 49
56
1691
90-8M0047659 JULY 2010 Page 2A-7

Ignition
Electrical Components PCM Mounting S/N 1B2270001B417701

4
1
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
Page 2A-8 90-8M0047659 JULY 2010

Ignition
Electrical Components PCM Mounting S/N 1B2270001B417701

Torque
2 5 Screw (M6 x 14) 6.8 60
3 5 Washer
5 2 Clip
6 1 PCM
7 8 Screw (M6 x 25) 6.8 60
8 3 Washer
9 3 Grommet
10 3 Bushing
11 1 Bracket
12 3 Relay assembly
13 3 Bracket
14 3 Grommet
15 3 Bushing
16 2 Pin
17 1 Spacer
18 1 Nut (M6) 6.8 60
19 1 Clip
20 1 Solenoid
21 2 Grommet
22 2 Bushing
23 2 Nut (1032) 2.5 22
24 2 Cap nut
25 1 Cable
26 2 Lockwasher
27 2 Nut (0.31218) 13.5 120
28 1 Cable assembly
29 1 Boot (yellow)
30 1 Trim harness
90-8M0047659 JULY 2010 Page 2A-9

Ignition
Electrical Plate Components S/N 1B2270001B417701

8
9
10
33 11 24
27
25
36 35 34 1
26
32
7
6
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
Page 2A-10 90-8M0047659 JULY 2010

Ignition
Electrical Plate Components S/N 1B2270001B417701

Torque
2 3 Coil
3 3 Hightension lead
4 3 Spark plug (NGK PZFR6H) 27 20
5 6 Screw (M6 x 30) 6.8 60
6 2 Clip
7 2 Screw (M6 x 12) 6.8 60
8 1 Sensor
9 1 Clip
10 1 Fitting
11 1 Tubing
12 1 Spacer
13 1 Fusible link (100 amp fuse)
14 1 Starter cable
15 1 Boot (red)
16 1 Engine harness
17 1 Fuse cover
18 1 Mini fuse (5 amp tan)
19 4 Mini fuse (20 amp yellow)
20 1 Connector (8 pin)
21 1 Clip
22 1 Battery cable
23 1 Boot (red)
24 3 Bushing
25 3 Washer
26 3 Screw (M8 x 35) 24.4 18
27 3 Grommet
28 1 Cover
29 3 Grommet
30 1 Cable
31 1 Pin
32 1 Tfitting
33 1 Tubing
34 1 Tubing
35 1 Coupler
36 1 Plug
37 1 Weather cap (6 pin)
38 1 Weather cap (male)
39 1 Connector cap (3 pin male)
90-8M0047659 JULY 2010 Page 2A-11

Ignition
Electrical Components S/N 1B417702 and Above

1 4
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
Page 2A-12 90-8M0047659 JULY 2010

Ignition
Electrical Components S/N 1B417702 and Above

Torque
2 5 Screw (M6 x 14) 6.8 60
3 5 Washer
5 2 Clip
6 1 PCM
7 10 Screw (M6 x 25) 10 88.5
8 3 Washer
9 3 Grommet
10 3 Bushing
11 1 Bracket
12 3 Relay assembly
13 3 Bracket
14 3 Grommet
15 3 Bushing
16 2 Pin
17 1 Spacer
18 1 Nut (M6) 10 88.5
19 1 Clip
20 1 Solenoid
21 2 Grommet
22 2 Bushing
23 2 Nut (1032) 2.5 22
24 2 Cap nut
25 1 Power stud assembly
26 1 Nut (M8) (stainless steel) 13.5 120
27 2 Lockwasher
28 2 Nut (0.31218) 13.5 120
29 1 Cable assembly
30 1 Boot (yellow)
31 1 Trim harness
32 1 Cable
33 1 Washer
34 1 Nut (M8) (stainless steel) 13.5 120
90-8M0047659 JULY 2010 Page 2A-13

Ignition
Throttle Body Components S/N 1B417702 and Above
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
Page 2A-14 90-8M0047659 JULY 2010

Ignition

Torque
1 1 Throttle body assembly
2 1 Retainer
3 4 Screw 11.3 100
4 1 Grommet
5 1 Grommet
6 1 Clamp (75.5 mm)
7 1 Screw
8 1 Washer
9 1 Washer
10 1 Bushing
11 1 Throttle lever kit
12 1 Throttle lever assembly
13 1 Lockwasher
14 1 Spool washer
15 1 Cupped washer
16 1 Screw (special)
17 1 Insert (75 HP) (90 HP)
18 1 Bracket
19 1 Screw (M6 x 16) 11.9 105
20 2 Cable
21 1 Cam
22 1 Bushing
23 1 Washer
24 1 Screw (M6 x 40) 10.7 95
25 1 Coupler
26 1 Throttle position sensor
27 2 Screw 2.7 24
28 2 Conduit
29 1 Clamp (75.5 mm)
90-8M0047659 JULY 2010 Page 2A-15

Ignition
Throttle Body Components S/N 1B417701 and Below
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
Page 2A-16 90-8M0047659 JULY 2010

Ignition

Torque
2 1 Retainer
3 4 Screw 11.3 100
4 1 Grommet
5 1 Grommet
6 1 Clamp
7 1 Screw
8 1 Spool washer
9 1 Cupped washer
10 1 Bushing
13 1 Lockwasher
14 1 Spool washer
15 1 Cupped washer
17 1 Roller
18 1 Bracket
19 3 Screw (M6 x 16) 11.9 105
20 2 Cable
21 1 Cam
22 1 Bushing
23 1 Washer
24 1 Screw (M6 x 40) 10.7 95
25 1 Coupler
27 3 Screw 2.7 24
28 1 Insert (75 HP) (90 HP)
29 1 Clamp (75.5 mm)
30 2 Conduit
90-8M0047659 JULY 2010 Page 2A-17

Ignition
Troubleshooting without a Computer Diagnostic System (CDS)

Troubleshooting without the computer diagnostic system (CDS) is limited to checking resistance on some of the sensors.
Typical failures usually do not involve the PCM. Connectors, setup, and mechanical wear are most likely at fault.
Verify the ignition coils are securely installed (pushed in) into the spark plugs.
The engine may not run or may not run above idle with the wrong spark plugs installed.
Swap ignition coils to see if the problem follows the coil or stays with the particular cylinder.
IMPORTANT: Disconnecting a sensor while the engine is running may result in a fault recording in the PCM Fault History. Use
the CDS to view the PCM fault history when troubleshooting/repair is completed.
If all cylinders exhibit similar symptoms, the problem is with a sensor or harness input to the PCM.
If problem is speed related or intermittent, it is probably connector or contact related. Inspect connectors for corrosion, loose
wires, or pins pushed back into connector. Verify the connectors are properly seated.
Inspect the harness for damage: pinched or cut wires and chafing.
Secure the grounds and all connections involving ring terminals. Apply Liquid Neoprene to all ring terminal connections.

25 Liquid Neoprene All ring terminal connections 92- 25711 3
Inspect the fuel pump harness connector for corrosion, loose wires, or pins pushed back into connector.
Check the fuel pump pressure.
Troubleshooting with the Computer Diagnostic System (CDS)

The computer diagnostic system (CDS) will help technicians diagnose and repair Mercury Marine 2 and 4cycle engines.
Attach the diagnostic cable to the PCM diagnostic connector to monitor sensors, PCM data values, and the status of the switches.
Use the 3 m (10 ft) extension cable to monitor the engine system while at the helm.
NOTE: The PCM software for 2004 model year does not support ignition load testing.
The PCM will record the state of the engine sensors and switches. The recorded information can be reviewed with the CDS to
help diagnose intermittent engine problems.
Refer to the CDS for complete diagnostic procedures.

Page 2A-18 90-8M0047659 JULY 2010

Ignition
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.
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Ignition
2. Engine Cranks, Starts, and Stalls

Cause Action
2.0 Low air pressure in rail Refer to 1.2.
2.1 Low fuel pressure in rail Refer to 1.2 and 1.3.
2.2 Abnormally high friction in engine Check for scuffed piston or other sources of high friction.
Refer to 1.3.
2.3 Air in fuel system/lines
Crank and start engine several times to purge.
Check motion of throttle arm.
2.4 TPS malfunction Stop nuts should contact block at idle and WOT.
Check TPS setup.
2.5 Remote control to engine harness connection is
Clean and inspect male and female connectors.
poor
3. Engine Idle is Rough

Cause Action
3.1 Low air pressure in rail (less than 79 2 psi while
Refer to 1.2.
running)
Replace spark plug:
If carbon bridges electrode gap or if it is completely black.
If it is not firing and is wet with fuel.
3.2 Fouled spark plug
NOTE: If spark plug is gray or completely black with aluminum specs, this
indicates a scuffed piston.
Wrong spark plug.
3.3 Failed direct injector Refer to specifications for ohm test.
3.3A Carboned/dirty injector Refer to service bulletins 200714 and 200812.
3.4 Failed fuel injector Refer to specifications for ohm test.
3.5 Bad coil/weak spark Refer to specifications for ohm test.
3.6 Flywheel misaligned during installation Remove flywheel and inspect.
4. Engine Idles Fast (RPM > 700) or Surges

Cause Action
4.1 Broken fuel pressure regulator or tracker Measure fuel pressure.
diaphragm Remove and inspect diaphragms (a special tool is required for assembly).
Check for fuel entering induction manifold or air compressor inlet.
4.2 Fuel leak
Fuel pump diaphragm leaking and/or vapor separator tank is flooding.
4.3 Tracker valve spring missing Inspect tracker valve for proper assembly.
4.4 Improper setup Check throttle cable and cam roller adjustment.
5. Engine Runs Rough Below 3000 RPM

Cause Action
5.1 Fouled spark plug Refer to 3.2.
5.2 Low air pressure in rail Refer to 1.2.
Check throttle cam setup on induction manifold.
Inspect linkage and roller.
5.3 Throttle incorrectly adjusted
If throttle plate stop screws have been tampered with, contact Mercury
Marine Service Department for correct adjustment procedures.
5.4 Bad coil/weak spark Refer to 3.5.
5.5 TPS malfunction Refer to 2.4.
Page 2A-20 90-8M0047659 JULY 2010

Ignition
6. Engine Runs Rough Above 3000 RPM

Cause Action
6.1 Fouled spark plug Refer to 3.2.
6.2 Speed reduction Refer to 7.
6.3 Low air pressure in rails Refer to 1.2.
6.4 TPS malfunction Refer to 2.4.
7. Speed Reduction (RPM reduced)

Cause Action
7.1 Low battery voltage (PCM cuts out below 8 volts) Check battery and/or alternator.
(fuel pump requires 9 volts) Check electrical connections.
7.2 Overheat condition (engine and/or air
Check water pump impeller/cooling system.
compressor)
7.3 Oil pump electrical failure Check electrical connection.
7.4 TPS failure
Check electrical connection.
If TPS fails, RPM is reduced to idle
8. Engine RPM Reduced to Idle Only

Cause Action
Refer to 2.4.
8.1 TPS failed
Use CDS to monitor system.
9. Loss of Spark on One Cylinder

Cause Action
9.1 Loose wire or pin connectors between PCM and
Check connectors.
coil primary
9.2 Faulty ignition coil Replace coil.
9.3 Faulty spark plug Replace spark plug.
9.4 Faulty spark plug wire Replace spark plug wire.2.
Theory of Operation Internal Ignition Coil Driver Models

When the ignition key is turned to the "RUN" position, battery voltage is supplied to the electrical system through the main power
relay. If the propulsion control module (PCM) does not sense engine rotation within a certain time period, the relay is turned off.
Engine rotation will engage the relay. When the main power relay is closed, voltage is supplied through the 20 amp ignition fuse
to the positive terminal on all of the ignition coils. Each coil contains an internal driver circuit. The driver circuit switches the primary
current on for a given time period (dwell), and then switches it off, collapsing the coil magnetic field creating a spark. The crankshaft
position sensor (CPS) reads the position pattern on the flywheel which allows the PCM to monitor the position of the crankshaft
while the engine is running. At the proper time for ignition spark, the PCM sends a signal to the coil driver to dwell and then provide
spark. When the engine is operating at lower RPM, this process is repeated in quick succession to provide a multistrike spark for
each combustion event. The number of strikes per event is varied depending on RPM and load requirements. The spark plug
platinum electrode and ground extends into the combustion chamber.
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.
90-8M0047659 JULY 2010 Page 2A-21

Ignition
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.
Serial number 1B417701 and

a b below
a - 5 amp fuse SmartCraft
5 20 circuit
20 20 b - 20 amp fuse Accessories
c - 20 amp fuse Ignition coil
d c circuit
d - 20 amp fuse Electric fuel
pump, PCM driver power,
oil pump circuit, fuel pump
circuit, and direct injectors
circuit
26686
a b c d e f
26685

a - 20 amp fuse Ignition coil circuit
b - 15 amp fuse Remote harness, main power relay, and cowl mounted trim switch
c - Spare 20 amp fuse
d - 20 amp fuse Electric fuel pump, PCM driver power, oil pump circuit, fuel pump circuit, and direct injectors circuit
e - 2 amp fuse Diagnostics circuit
f - 5 amp fuse SmartCraft circuit
Propulsion Control Module (PCM)

The PCM requires 8 VDC minimum to operate. If the PCM should fail, the engine will stop running. Some inputs to the PCM can
be monitored and tested using the computer diagnostic system (CDS).
NOTE: The 2004 model year PCM software does not support ignition load tests.
The PCM controls the following functions:

Calculates the precise fuel and ignition timing requirements based on engine speed, throttle position, manifold pressure,
manifold air temperature, and cylinder block coolant temperature.
Directly controls the ground circuit to: fuel injectors, ignition coil driver, main power relay activation, diagnostics, Engine
Guardian, tachometer link (analog tachometer output or link gauge driver).
Indirectly controls the positive circuit to: fuel injectors, ignition coils, main power relay activation, trim up, trim down.
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Ignition
When the key switch is moved to the "RUN" position, but the engine is not started, the PCM completes the ground circuit for the
main power relay and a 5 VDC reference to the engine sensors. The PCM monitors engine sensors, SmartCraft vessel sensors,
and will transmit fault information from these sensors to the helm. Once the engine has started, the PCM controls and monitors
all engine functions, and communicates with the command module over the CAN bus system. With the ignition key switch "OFF,"
the PCM allows the trim system to function for up to 15 minutes (on select models).
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.
1. Disconnect the battery cables from the battery.

2. Disconnect the two wire harness retaining clips.
3. Remove the screw securing the fuse holder to the PCM.
4. Disconnect the engine harness connectors from the PCM.
b a - Wire harness retaining clip

b - Screw securing fuse holder
c - Engine harness connector
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.
1. Install the grommets onto the PCM.
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Ignition
2. Install the bushings into the grommets.
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

Screw (3) 4 35
4. Secure the fuse holder to the PCM with a screw. Tighten the screw to the specified torque.

Screw 4 35
5. Secure the wire harness with the two retaining clips.
6. Connect the engine harness connectors to the PCM.
b a - Wire harness retaining clip

b - Screw securing fuse holder
c - Engine harness connector
a
c
26827
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Ignition
Main Power Relay (MPR)

The main power relay (MPR) is located on the starboard side of the engine. The MPR is controlled by the PCM. After the first
system power up, the MPR is active for approximately five seconds. The PCM will deactivate the MPR unless the crankshaft
position sensor signals the PCM to initiate the MPR. The main power relay supplies 12 volts to the lowpressure fuel pump,
highpressure fuel pump, oil pump, ignition coils, and the fuel injectors.
28309
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
Main Power Relay Test

The main power relay can be tested with the computer diagnostic system (CDS).

Use the DMT 2004 digital multimeter for all of the following tests.
1. Disconnect the engine harness from the main power relay.

2. Perform a visual inspection of the main power relay spade terminals. Look for loose or corroded spade terminals.
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Ignition
3. Measure the resistance between the main power relay coil terminals 85 (red/purple) and terminal 86 (yellow/purple). Replace
the relay if the resistance is not within the specifications.
87
87a
86 85
30
7602
Meter Test Leads

Meter Scale Reading ()
Red Black
Terminal 85 Terminal 86 Auto ohms 85 10 ohms
Page 2A-26 90-8M0047659 JULY 2010

Ignition
Main Power Relay Circuit Diagram S/N 1B417702 and Above

BLK
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
90-8M0047659 JULY 2010 Page 2A-27

Ignition
Main Power Relay Circuit Diagram S/N 1B2270001B417701

BLK
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
Page 2A-28 90-8M0047659 JULY 2010

Ignition
Main Power Relay Circuit Diagram S/N 0T8010001B226999
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
90-8M0047659 JULY 2010 Page 2A-29

Ignition
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

2. Remove the flywheel cover from the engine.
3. Disconnect all of the spark plug leads from the spark plugs.
4. Remove the accessory drive belt.
5. Hold the flywheel with the flywheel holding tool. Loosen the flywheel nut four turns out from a light seat.
a - Flywheel holder
a
9753
6. Install the flywheel puller into the flywheel.
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Ignition
7. Hold the flywheel with the flywheel holding tool and tighten the flywheel puller bolt until the flywheel is loose.
9757
a - Flywheel puller
Flywheel Puller 9173687A2

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

Flywheel nut 163 120
5. Install the accessory drive belt.
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Ignition
Ignition Coil 3 Cylinder OptiMax

When the ignition key is turned to the "RUN" position, battery voltage is supplied to the electrical system through the main power
relay. If the propulsion control module (PCM) does not sense engine rotation within a certain time period, the relay is turned off.
Engine rotation will engage the relay. When the main power relay is closed, voltage is supplied through the 20 amp ignition fuse
to the positive terminal on all of the ignition coils. Each coil contains an internal driver circuit. The driver circuit switches the primary
current on for a given time period (dwell), and then switches it off, collapsing the coil magnetic field and creating a spark. The
crankshaft position sensor (CPS) reads the position pattern on the flywheel, which allows the PCM to monitor the position of the
crankshaft while the engine is running. At the proper time for ignition spark, the PCM sends a signal to the coil driver to dwell and
then provide spark. When the engine is operating at lower RPM, this process is repeated in quick succession to provide a
multistrike spark for each combustion event. The number of strikes per event is varied depending on RPM and load requirements.
The spark plug platinum electrode and ground extends into the combustion chamber.
a - Ignition coils
9634
Spark Plug Lead Ohm Test

Spark plug leads are directional. The boot with the support webbing must be installed on the spark plug. The other boot has a
slightly larger inside diameter and ribs inside the boot to help with retention to the ignition coil tower.
Use the DMT 2004 digital multimeter to check the ignition spark plug lead. Replace the ignition spark plug lead if the resistance
is not within specification.
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
Meter Test Leads

Red Black
Spark plug boot end Ignition coil boot end Auto 11701330
Ignition Coil Removal

1. Remove the spark plug lead from the spark plug.
2. Disconnect the engine harness connectors from the ignition coils.
Page 2A-32 90-8M0047659 JULY 2010

Ignition
3. Remove the screws securing the ignition coils to the ignition plate.
a - Ignition coil harness

b - Spark plug leads
c - Screws securing the ignition coils
a
c
b
9733
Ignition Coil Installation

1. Secure the ignition coil to the ignition plate with two screws. Tighten the screws to the specified torque.
2. Connect the engine harness connectors into the ignition coils.
3. Install the spark plug leads onto the spark plugs.
a - Ignition coil harness

b - Spark plug leads
c - Screws securing the ignition coils
a
c
b
9733

Screws (M6 x 30) 6.8 60
90-8M0047659 JULY 2010 Page 2A-33

Ignition
Ignition Coil Test

PCM Failures Due to Failed Ignition Coil (SB 200725R2)
The PCM can fail from a faulty ignition coil. The failures occur from a short between the 12 volt supply to the ignition coil and the
electronic spark trigger (EST) low, or the ground circuit of the ignition coil. A short of this type will supply 12 volts directly to the
EST ground circuit in the PCM, failing that circuit, resulting in a no spark condition on all cylinders.
To confirm the EST ground circuit in the PCM is damaged, a resistance check between B1 and C24 pin on the PCM should indicate
an open circuit or high resistance value if it has failed. A good PCM will measure as a short, or very low resistance. A good PCM
normal resistance is 0.5 ohm or less.
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.
Page 2A-34 90-8M0047659 JULY 2010

Ignition
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
Black Meter Lead

Secondary Secondary Primary Battery (+)
EST Pin A EST Pin B
Tower Low Pin C Ground Pin D Pin E
Secondary
X No continuity No continuity 28 megaohm No continuity No continuity
tower
850012000 2900050000 1100021000
EST pin A No continuity X No continuity
ohm ohm ohm
Red Meter 850012000 3900051000 2100031000
EST low pin B No continuity X No continuity
Lead ohm ohm ohm
Secondary low
No continuity No continuity No continuity X No continuity No continuity
pin C
Primary ground 2000050000 3100051000 1300023000
No continuity No continuity X
pin D ohm ohm ohm
1100021000 2100031000 1300023000
Battery (+) pin E No continuity No continuity X
ohm ohm ohm
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.
90-8M0047659 JULY 2010 Page 2A-35

Ignition
Ignition Coil Circuit Schematic
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
1.5L OptiMax Digital Signal Example
a - EST digital signal

f b - 5 volts
c
c - Total ignition
sequence
b Multistrike at lower
a RPM
d - Dwell starts
d e g h e - End of dwell (ignition
fires)
24930
f - Total ignition
sequence Single
strike at higher RPM
g - Dwell starts
h - End of dwell (ignition
fires)
Page 2A-36 90-8M0047659 JULY 2010

Ignition
Crankshaft Position Sensor (CPS)

The crankshaft position sensor (CPS) is a hall effect switch that senses the collapse of a magnetic field. The lower part of the
flywheel is cast with a position pattern. As the flywheel rotates, the CPS senses the location of the crankshaft by the collapse of
the magnetic field caused by the pattern passing the CPS. The CPS supplies trigger signal information to the PCM. The PCM
utilizes the trigger signal to determine engine RPM, fuel delivery, spark timing, and over revolution protection. The CPS is not
adjustable.
a - Crankshaft position sensor
a 9640
Crankshaft Position Sensor Test

1. Perform a visual inspection of the sensor. The tip of the sensor must be flush across the end; if not, replace the sensor.
2. The tip of the sensor must be clear of metal debris (ring gear filings).
NOTE: A magnet is mounted in the sensor tip. If the magnet is missing, the sensor will not operate properly.
3. Inspect the flywheel pattern for:
Excessive corrosion.
The teeth should have square edges.
Only one open space on either side of the pattern groups.
4. Replace the flywheel if it does not meet inspection requirements.
5. Inspect the sensor pins and the wires coming from the connector. Look for broken, bent, or corroded pins at the sensor; and
loose, broken, or corroded wires at the connector.
6. Disconnect the engine harness connector from the sensor. Use the DMT 2004 digital multimeter to measure the resistance
across the sensor pins. Replace the sensor if out of specification.
90-8M0047659 JULY 2010 Page 2A-37

Ignition
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
Crankshaft Position Sensor

Crankshaft Position Sensor Removal

1. Remove flywheel cover and electrical cover.
2. Disconnect the engine harness connector from the crankshaft position sensor.
3. Remove the two screws securing the crankshaft position sensor to the cylinder block.
a - Engine harness connector

b b - Screw securing the crankshaft position sensor (2)
26822
Crankshaft Position Sensor Installation

1. Install the crankshaft position sensor onto the cylinder block and secure with two screws. Tighten the screws to the specified
torque.
Page 2A-38 90-8M0047659 JULY 2010

Ignition
2. Connect the engine harness connector to the crankshaft position sensor.

b b - Screw securing the crankshaft position sensor (2)
26822

CPS screw (M5 x 16) (2) 5 44.2
3. Install the electrical cover.
4. Install the flywheel cover.
Throttle Position Sensor (TPS)

The throttle position sensor transmits throttle angle information to the PCM. The PCM uses the throttle angle information, along
with other sensors, to regulate fuel injector volume (pulse width) and ignition timing. Should the sensor fail, a warning horn will
sound and engine RPM will be reduced. The TPS is not adjustable. The TPS position can be monitored with the computer
diagnostic system (CDS). Voltage change should be smooth from idle to wideopen throttle. If the voltage change is erratic, the
TPS is defective.
Throttle Position Sensor Voltage Specifications

Idle 0.171.05 VDC
Wideopen throttle 3.764.64 VDC
26865
2007 and newer
90-8M0047659 JULY 2010 Page 2A-39

Ignition
2006 and prior

a - Throttle position sensor
9641
Throttle Position Sensor Removal S/N 1B417702 and Above

1. Disconnect the engine wire harness connector from the TPS.
2. Remove the two screws securing the TPS to the throttle lever bracket. Remove the TPS from the throttle lever bracket.
a - Engine wire harness connector

b - Screw securing the TPS (2)
a
26905
Throttle Position Sensor Installation S/N 1B417702 and Above

1. Align the TPS with the throttle lever bracket and the throttle lever coupler.
a - Throttle lever bracket

b - Throttle lever coupler
a
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.

4. Secure the TPS to the throttle lever bracket with two screws. Tighten the screws to the specified torque.
Page 2A-40 90-8M0047659 JULY 2010

Ignition
5. Connect the engine wire harness connector to the TPS.
a - Engine wire harness connector

b - Screw securing the TPS (2)
a
26905

Screw (2) 5 44.2
Throttle Position Sensor Removal S/N 1B417701 and Below

1. Disconnect the engine wire harness connector from the TPS.
2. Remove the three screws securing the TPS to the 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
Throttle Position Sensor Installation S/N 1B417701 and Below

1. Align the TPS with the throttle lever coupler.
2. Apply Loctite 271 Threadlocker to the threads of the three screws that secure the TPS to the throttle lever bracket.

3. Install the TPS to the throttle lever bracket and secure with three screws. Tighten the screws to the specified torque.

Screw (3) 5 44.2
90-8M0047659 JULY 2010 Page 2A-41

Ignition
4. Connect the engine wire harness connector to the TPS.
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
Throttle Position Sensor (TPS) Troubleshooting

If the throttle position sensor is out of the intended operating range when the engine is started, the PCM will determine if the TPS
has failed. The warning horn will sound, the check engine light will illuminate, and the engine will go into RPM reduction. When
the engine is started, the throttle arm on the engine must be against the idle stop screw.
Check the throttle cable adjustment. The throttle arm stop screw must be against the throttle stop on the cylinder block when
the engine is started.
Verify the operator is not advancing the foot throttle where applicable, or advancing the throttle only on the remote control.
Check the throttle cam to roller adjustment. If the roller is not in the pocket area on the cam, the roller may ride up or down
on the cam, causing the TPS values to change.
Cylinder Block Coolant Temperature Sensor

The cylinder block coolant temperature sensor is located above and to the left of cylinder number one spark plug. It is a thermistor
immersed in the engine coolant path and supplies the PCM with engine temperature information. The PCM adjusts the timing and
the amount of fuel delivered according to the water temperature in the cylinder block. Low coolant temperature produces high
resistance, while high temperature causes low resistance.
a - Cylinder number one spark plug

b b - Cylinder block coolant temperature sensor
26966
Page 2A-42 90-8M0047659 JULY 2010

Ignition
Cylinder Block Coolant Temperature Sensor Test

The CDS will provide a numerical readout of the block coolant temperature before and after the engine is started. With the engine
not running, block temperature should be approximately the same as the ambient air temperature. After the engine is started, the
temperature sensor should indicate a rise in coolant temperature to approximately 54.470 C (130158 F) at idle RPM. Outside
air temperature and the temperature of the water the engine is operating in will directly affect the engine block temperature.
NOTE: When the engine RPM is increased, the poppet valve will open and the engine temperature will drop.
1. With the engine running and the CDS connected to the engine, if the cylinder block coolant temperature sensor does not
indicate a temperature change, move the sensor harness and connector. If the temperature changes, look for a broken, loose,
or corroded wire.

2. Disconnect the engine harness connector from the cylinder block coolant temperature sensor.
3. Inspect the cylinder block coolant temperature sensor pins and the wires coming from the connector. Look for broken, bent,
or corroded pins on the sensor; and loose, broken, or corroded wires on the connector.
4. The cylinder block coolant temperature sensor can be tested with an ohmmeter by removing the sensor from the cylinder
block and heating or cooling the end of the sensor in a temperature controlled media. If the readings do not match those in
the table, replace the cylinder block coolant temperature sensor and retest.
b a - Pin A
b - Cylinder block coolant temperature sensor
c - Pin B
a c
16973
Meter Test Leads

Temperature Reading ()
Red Black
0 C (32 F) 32.6 k 1.14
25 C (77 F) 10.0 k 1.14
Pin B Pin A
50 C (122 F) 3.6 k 1.50
100 C (212 F) 678.0 2.36
5. If the cylinder block coolant temperature sensor is serviceable, perform an ohm check on the wiring between the sensor
connector and the PCM.
Cylinder Block Coolant Temperature Sensor Removal

1. Disconnect the engine harness connector from the cylinder block coolant temperature sensor.
90-8M0047659 JULY 2010 Page 2A-43

Ignition
2. Remove the cylinder block coolant temperature sensor from the cylinder block.

26966
Cylinder Block Coolant Temperature Sensor Installation

1. Install a new Oring onto the cylinder block coolant temperature sensor.
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

Cylinder block coolant temperature sensor 15 132.7
Page 2A-44 90-8M0047659 JULY 2010

Ignition
Air Compressor Head Temperature Sensor

The air compressor head temperature sensor is a thermistor immersed in the coolant path of the air compressor and supplies the
PCM with air compressor temperature information. The PCM monitors this temperature and warns the operator of a potentially
damaging high temperature. The PCM activates the warning horn and will limit engine RPM. A low temperature produces high
resistance, while a high temperature causes low resistance.
26974
Air Compressor Head Temperature Sensor Test

The CDS will help determine the proper functioning of the air compressor head temperature sensor by providing a numerical
readout of the air compressor head temperature before and after the engine is started. With the engine not running, the air
compressor head temperature should be approximately the same as the ambient air temperature. After the engine is started, the
temperature sensor should indicate a rise in the air compressor head temperature. Outside air temperature and the temperature
of the water the engine is operating in will directly affect the air compressor head temperature.
1. With the engine running and the CDS connected to the engine, if the air compressor head temperature sensor does not appear
to be indicating a temperature change, shake or move the sensor harness and connector. If the temperature begins to change,
look for a broken, loose, or corroded wire.

2. Disconnect the engine harness connector from the air compressor head temperature sensor.
3. Perform a visual inspection of the air compressor head temperature sensor pins and the wires coming from the connector.
Look for broken, bent, or corroded pins at the air compressor head temperature sensor; and loose, broken, or corroded wires
at the connector.
4. The air compressor head temperature sensor can be tested with an ohmmeter by removing the sensor from the air compressor
and heating or cooling the end of the sensor in a temperature controlled media. If the readings do not match those in the table,
replace the air compressor head temperature sensor and retest.
b a - Pin A
b - Air compressor head temperature sensor
c - Pin B
a c
16973
90-8M0047659 JULY 2010 Page 2A-45

Ignition
Meter Test Leads

Red Black
0 C (32 F) 32.6 k 1.14
25 C (77 F) 10.0 k 1.14
Pin B Pin A
50 C (122 F) 3.6 k 1.50
100 C (212 F) 678.0 2.36
5. If the ohm check indicates that the air compressor head temperature sensor is serviceable, perform an ohm check of the
wiring between the air compressor head temperature sensor connector and the PCM.
Air Compressor Head Temperature Sensor Removal

1. Disconnect the engine harness connector from the air compressor head temperature sensor.
2. Remove the air compressor head temperature sensor from the air compressor.

a b b - Air compressor head temperature sensor
26976
Air Compressor Head Temperature Sensor Installation

1. Install a new Oring onto the air compressor head temperature sensor.
2. Apply Loctite 567 PST Pipe Sealant to the threads of the air compressor head temperature sensor.
13384

9 Air compressor head temperature sensor threads 92-809822
Sealant
3. Install the air compressor head temperature sensor into the air compressor. Tighten the air compressor head temperature
sensor to the specified torque.
Page 2A-46 90-8M0047659 JULY 2010

Ignition
4. Connect the engine harness connector to the air compressor head temperature sensor.

a b b - Air compressor head temperature sensor
26976

Air compressor head temperature sensor 15 132.7
Manifold Absolute Pressure (MAP) Sensor

The MAP sensor measures the changes in the intake manifold pressure and is located at the top of the intake manifold. When
the ignition key switch is turned to the "ON" position, the MAP sensor reads the ambient atmospheric pressure. This information
is used by the PCM as an indication of altitude. The MAP sensor will change as a result of engine load and speed.
26978
Manifold Absolute Pressure Sensor Test

1. Start the engine and connect the CDS to the engine. If the MAP sensor does not appear to be indicating a pressure change,
shake or move the sensor harness and connector. If the pressure begins to change, look for broken, loose, or corroded wires.

2. Turn the ignition key switch to the "OFF" position. Disconnect the engine harness connector from the MAP sensor.
3. Visually inspect the MAP sensor pins and the wires coming from the connector. Look for broken, bent, or corroded pins at
the MAP sensor; and loose, broken, or corroded wires at the engine harness connector.
90-8M0047659 JULY 2010 Page 2A-47

Ignition
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
Meter Test Leads Meter Scale Reading ()

Red Black at 20 C (68 F)
A B Auto 4.28 k 30%
A C Auto 98.6 k 30%
B A Auto 4.28 k 30%
B C Auto 102.6 k 30%
C A Auto 98.6 k 30%
C B Auto 102.6 k 30%
5. If the ohm check of the MAP sensor indicates that the MAP sensor is serviceable, perform an ohm check on the wiring between
the MAP sensor connector and the PCM.
Manifold Absolute Pressure Sensor Removal

1. Disconnect the engine harness connector from the MAP sensor.
2. Remove the screw securing the MAP sensor retaining bracket.
3. Pull the MAP sensor from the intake manifold.
a a - Engine harness connector

b b - Retaining bracket
c - Screw
26979
Manifold Absolute Pressure Sensor Installation

1. Push the MAP sensor into the intake manifold opening.
2. Connect the engine harness connector to the MAP sensor.
3. Install the MAP sensor retaining bracket onto the intake manifold.
Page 2A-48 90-8M0047659 JULY 2010

Ignition
4. Secure the retaining bracket with a screw. Tighten the screw to the specified torque.

b b - Retaining bracket
c - Screw
26979

MAP sensor retaining bracket screw 10.2 90
Manifold Air Temperature (MAT) Sensor

The MAT sensor is a thermistor that controls a signal voltage to the PCM and is located in the lower part of the intake manifold.
It informs the PCM of the air temperature inside the intake manifold. The PCM adjusts the fuel injection duration needed to run
the engine at optimum efficiency according to the MAT information. When the intake air is cold, the sensor resistance is high. As
the air temperature rises, resistance lowers.
26983
Manifold Air Temperature Sensor Test

The CDS will determine the proper functioning of the MAT sensor by providing a numerical readout of the sensor temperature
before and after the engine is started. With the engine not running, intake air temperature should be approximately the same as
the ambient air temperature. After the engine is started, the temperature sensor should indicate a rise in air intake temperature.
Outside air temperature will directly affect the engine manifold air intake temperature.
1. Start the engine and connect the CDS to the engine. If the MAT sensor does not appear to be indicating a temperature change,
shake or move the sensor harness and connector. If the temperature begins to change, look for a broken, loose, or corroded
wire.

2. Disconnect the engine harness connector from the MAT sensor.
3. Visually inspect the MAT sensor pins and the wires coming from the engine harness connector. Look for broken, bent, or
corroded pins at the MAT sensor; and loose, broken, or corroded wires at the engine harness connector.
4. Use the DMT 2004 digital multimeter to test the MAT sensor. Remove the MAT sensor from the intake manifold.
90-8M0047659 JULY 2010 Page 2A-49

Ignition
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
Meter Test Leads

Red Black
0 C (32 F) 32.6 k 1.14
25 C (77 F) 10.0 k 1.14
Pin B Pin A
50 C (122 F) 3.6 k 1.50
100 C (212 F) 678.0 2.36
6. If the ohm check of the MAT sensor indicates that the MAT sensor is serviceable, perform an ohm check of the wiring between
the sensor connector and the PCM.
Manifold Air Temperature Sensor Removal

1. Disconnect the engine harness connector from the MAT sensor.
2. Remove the MAT sensor from the intake manifold.

b - Manifold air temperature sensor
a b
26985
Manifold Air Temperature Sensor Installation

1. Install a new Oring onto the MAT sensor.
13384
2. Install the MAT sensor into the intake manifold. Tighten the MAT sensor to the specified torque.
Page 2A-50 90-8M0047659 JULY 2010

Ignition
3. Connect the engine harness connector to the MAT sensor.

b - Manifold air temperature sensor
a b
26985

Manifold air temperature sensor 15 132.7
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
a - Shift interrupt switch
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.
Guardian Protection System

The Guardian Protection System monitors critical engine functions and will reduce engine power accordingly in an attempt to keep
the engine running within safe operating parameters.
If a sensor fails, the PCM will compensate so the engine will not go into a rich condition. Disconnecting a sensor for troubleshooting,
may have no noticeable effect and be misleading the diagnosis of the engine. All sensor failures will be recorded and stored in
the PCM.
90-8M0047659 JULY 2010 Page 2A-51

Ignition
IMPORTANT: The Guardian System cannot guarantee that powerhead damage will not occur when adverse operating conditions
are encountered. The Guardian System is designed to 1) warn the boat operator that the engine is operating under adverse
conditions and 2) reduce power by limiting maximum RPM in an attempt to avoid or reduce the possibility of engine damage. The
boat operator is ultimately responsible for proper engine operation.
Guardian System Activation

Condition Result
Engine power level can be reduced to any percentage down to a fast idle, if overheat condition
Engine overheat
persists.
Air compressor overheat Warning horn is activated, but there is no power reduction.
Engine power level can be reduced to any percentage down to a fast idle, if overheat condition
Block water pressure low
persists.
If the throttle position sensor fails or becomes disconnected, power will be limited to a
Throttle position sensor failure maximum of approximately 4500 RPM. When the TPS is in the fail mode, the PCM will use
the MAP sensor for a reference to determine fuel calibration.
Temperature sensor (cylinder If a temperature sensor should fail or become disconnected, power will be limited to a
head and air compressor) failure maximum of approximately 4500 RPM.
Battery voltage greater than 16 volts or less than 10 volts will result in engine output power
Battery voltage (too high or too being reduced. The higher or lower the voltage is outside of these parameters, the greater
low) the percentage of power reduction. In an extreme case, power could be reduced to a fast
idle.
If the oil pump fails or an open circuit occurs between the pump and the PCM, engine power
Oil pump failure
will be reduced to a fast idle.
Engine Overspeed Protection System

The system is activated when the engine speed exceeds the maximum allowable RPM.
Overspeed activation for outboard engines with S/N 1B417701 and below, the warning horn will sound continuously. Outboard
engines with S/N 1B417702 and above, the warning horn is disabled. All engines with overspeed protection, will automatically
reduce the engine speed to within the allowable limits.
Warning Horn Signals

When the key switch is turned to the "ON" position, the horn will turn on for a moment as a test to show the horn is working.
The warning horn will emit either a continuous beep or intermittent short beeps. This will alert the operator and help identify the
following listed situations. For visual display of the specific engine functions and for additional engine data, refer to SmartCraft
Product information, following.
Warning Horn
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.
Page 2A-52 90-8M0047659 JULY 2010

Ignition
Warning Horn
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.
90-8M0047659 JULY 2010 Page 2A-53

Ignition
Notes:
Page 2A-54 90-8M0047659 JULY 2010

Charging and Starting System
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
90-8M0047659 JULY 2010 Page 2B-1


Alternator output (regulated)
Output at the battery at 2000 RPM 3238 amps
Output at the alternator at 2000 RPM 5260 amps
Voltage set point 14.5 0.25 volts
Regulator current draw1.
Ignition switch "OFF" 0.585 mA
Ignition switch "ON" 150.0 mA
Starter draw
Under load 200 amps
No load 65 amps
Average engine RPM when cranking 300325 RPM
Starter solenoid current draw at 12.6 volts
Pull in coil 40 amps
Hold in coil 10 amps
Start solenoid current draw 4 amps
Starter brush length (minimum) 6.35 mm (0.25 in.)
Battery rating (minimum)
Marine cranking amperes 1000
Cold cranking amperes 800
Ampere hour (Ah) 180

7 Loctite 271 Threadlocker Alternator mounting screw threads 92-809819
Alternator ground screw and ring terminal
Starter brush wire terminals
Starter ground wire screw
Starter ground and solenoid terminals
Battery terminal bolts
95 2-4-C with Teflon 92-802859A 1
Starter solenoid plunger
Special Tools

V Hz
H z TEMP
mA
mV IG
OFF IP
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.
Page 2B-2 90-8M0047659 JULY 2010

Notes:
90-8M0047659 JULY 2010 Page 2B-3

Flywheel/Alternator
15
6
17
7
16
8 1
13
11
14 2
12
10
3
14 1683
Page 2B-4 90-8M0047659 JULY 2010

Flywheel/Alternator
Torque
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
90-8M0047659 JULY 2010 Page 2B-5

Starter Motor Components

2
6
5
9
8 3
11 1
10
12
7
13 1339
Page 2B-6 90-8M0047659 JULY 2010

Starter Motor Components

Torque
1 1 Starter assembly
2 2 Through bolt
3 1 Gear kit
4 1 Solenoid
5 1 Bolt with washer (0.25020 x 0.625) 9 80
6 1 Cable
7 1 Decal
8 1 Lockwasher
9 1 Nut (M5) 2.5 22
10 1 Lockwasher
11 1 Nut (M8) 6 55
12 2 Collar
13 1 Stop
90-8M0047659 JULY 2010 Page 2B-7

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.
Original Battery Cable Length and Gauge Shipped with Engine

Original Equipment Battery Cable Length/Wire Gauge Size Shipped with Engine
Models (HP) Cable Length Wire Gauge Size
625 (2 and 4Stroke 400 cc [24.4 in] or less) 2.4 m (8 ft) 8
25115 (except OptiMax) 2.4 m (8 ft) 6
125250 (except OptiMax) 3.0 m (10 ft) 6
OptiMax/Verado 3.7 m (12 ft) 4
75/80/90/100/115 EFI FourStroke (2006 and newer) 3.7 m (12 ft) 4
Battery Cable Size for Outboard Models

IMPORTANT: Only use copper battery cables. Do not use aluminum cables for any outboard marine installations.
If longer battery cables are required, the wire gauge size must increase. See chart following for correct wire gauge size.
a a - Wire gauge size

b - Battery cable length
b
2758
Page 2B-8 90-8M0047659 JULY 2010

Copper Battery Cable Wire Gauge Size

Wire Gauge Size Number SAE
OptiMax, Verado, 75
625 hp (2 and 4Stroke 25115 hp (except 125250 hp (except
Models 115 EFI FourStroke
400 cc [24.4 in] or less) OptiMax) OptiMax)
(2006 and newer)
2.4 m (8 ft) 8 6
2.7 m (9 ft) 6 4
3.0 m (10 ft) 6 4 6
3.4 m (11 ft) 6 4 4
3.7 m (12 ft) 6 4 4 4
4.0 m (13 ft) 6 2 4 2
4.3 m (14 ft) 4 2 4 2
4.6 m (15 ft) 4 2 4 2
4.9 m (16 ft) 4 2 2 2
5.2 m (17 ft) 4 2 2 2
5.5 m (18 ft) 4 2 2 2
5.8 m (19 ft) 4 2 2 2
6.1 m (20 ft) 4 2 2 2
6.4 m (21 ft) 2 1 2 1
6.7 m (22 ft) 2 1 2 1
7.0 m (23 ft) 2 1 2 1
Cable Length 7.3 m (24 ft) 2 1 2 1
7.6 m (25 ft) 2 1 2 1
7.9 m (26 ft) 2 1/0 1 1/0
8.2 m (27 ft) 2 1/0 1 1/0
8.5 m (28 ft) 2 1/0 1 1/0
8.8 m (29 ft) 2 1/0 1 1/0
9.1 m (30 ft) 2 1/0 1 1/0
9.4 m (31 ft) 2 1/0 1 1/0
9.8 m (32 ft) 2 1/0 1 1/0
10.1 m (33 ft) 2 2/0 1/0 2/0
10.4 m (34 ft) 2 2/0 1/0 2/0
10.7 m (35 ft) 1 2/0 1/0 2/0
11.0 m (36 ft) 1 2/0 1/0 2/0
11.3 m (37 ft) 1 2/0 1/0 2/0
11.6 m (38 ft) 1 2/0 1/0 2/0
11.9 m (39 ft) 1 2/0 1/0 2/0
12.2 m (40 ft) 1 2/0 1/0 2/0
90-8M0047659 JULY 2010 Page 2B-9

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.
Charging a Discharged Battery

! 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.
The following basic rules apply to any battery charging situation:

1. Any battery may be charged at any rate (in amperes), or as long as spewing of electrolyte (from violent gassing) does not
occur, and for as long as electrolyte temperature does not exceed 52 C (125 F). If spewing of electrolyte occurs, or if
electrolyte temperature exceeds 52 C (125 F), charging rate (in amperes) must be reduced or temporarily halted to avoid
damage to the battery.
2. Battery is fully charged when, over a 2 hour period at a low charging rate (in amperes), all cells are gassing freely (not spewing
liquid electrolyte), and no change in specific gravity occurs. Full charge specific gravity is 1.2601.275, corrected for electrolyte
temperature with electrolyte level at 4.8 mm (3/16 in.) over plate, unless electrolyte loss has occurred (from age or overfilling),
in which case, specific gravity reading will be lower. For most satisfactory charging, lower charging rates in amperes are
recommended.
3. If, after prolonged charging, specific gravity of at least 1.230 on all cells cannot be reached, battery is not in optimum condition
and will not provide optimum performance; however, it may continue to provide additional service, if it has performed
satisfactorily in the past.
4. To check the battery voltage while cranking the engine with an electric starting motor at ambient air temperature of 23.8 C
(75 F), place the red (+) lead of the tester on the positive (+) battery terminal and the black () lead of the tester on the
negative () battery terminal. If the voltage drops below 101/2 volts while cranking, the battery is weak and should be
recharged or replaced.
Page 2B-10 90-8M0047659 JULY 2010

Winter Storage of Batteries

Battery companies are not responsible for battery damage, either in winter storage or in dealer stock, if the following instructions
are not observed:
1. Remove battery from its installation as soon as possible and remove all grease, sulfate, and dirt from the top surface by
running water over top of the battery. Be sure, however, the vent caps are tight beforehand and blow off all excess water
thoroughly with compressed air. Check water level, making sure the plates are covered.
2. When adding distilled water to the battery, be extremely careful not to fill more than 4.8 mm (3/16 in.) above perforated baffles
inside the battery. Battery solution or electrolyte expands from heat caused by charging. Overfilling the battery will cause the
electrolyte to overflow (if filled beyond 4.8 mm [3/16 in.] above baffles).
3. Grease terminal bolts well with 24C with Teflon and store the battery in a cooldry place. Remove the battery from storage
every 3045 days, check the water level, and put on charge for 5 or 6 amps. Do not fast charge.

95 2-4-C with Teflon Battery terminal bolts 92-802859A 1
4. If specific gravity drops below 1.240, check battery for reason and recharge. When gravity reaches 1.260, discontinue
charging. To check specific gravity, use a hydrometer, which can be purchased locally.
5. Repeat preceding charging procedure every 3045 days, as long as the battery is in storage, for best possible maintenance
during inactive periods to ensure a good serviceable battery in spring. When ready to place the battery back in service, remove
excess grease from the terminals (a small amount is desirable on terminals at all times), recharge again, as necessary, and
reinstall the battery.
Alternator System
BLK Black BLU Blue
BRN Brown GRY Gray
RED Red TAN Tan
90-8M0047659 JULY 2010 Page 2B-11

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
S/N 1B417702 and above

a - Power stud
b - Start solenoid
c - Starter
d - 15 amp fuse Main power relay, engine harness
e - Alternator ground
f - Alternator
g - Alternator sense and excitation leads
h - 100 amp fusible link
i - Battery
j - 14 pin harness connector
Page 2B-12 90-8M0047659 JULY 2010

BLK
b
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
90-8M0047659 JULY 2010 Page 2B-13

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.
Page 2B-14 90-8M0047659 JULY 2010

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.
Diagnosis of Alternator System on the Engine

1. If the battery is undercharged, verify the condition is not caused by excessive accessory current draw or by accessories which
have been accidentally left on.
2. Check the physical condition and the state of the battery charge. The battery must be 75% (1.230 specific gravity) or greater
to obtain valid results in the following tests. Charge the battery if it does not show the minimum 75% state of charge.
3. Inspect the entire alternator system wiring for defects. Check all connections for tightness and cleanliness, particularly the
battery cable clamps and battery terminals.
4. The alternator mounting bracket has rubber isolation mounts. Ensure the alternator ground cable is secured to the alternator
and the cylinder block.
IMPORTANT: The red fusible link on the alternator must be tight. A discolored insulator sleeve indicates the lead was loose
and becoming hot. Verify the fusible link attaching locknut is torqued to specification.
a - Fusible link
29692

Locknut 5.6 50
90-8M0047659 JULY 2010 Page 2B-15

5. Check the belt for excessive wear, cracks, glazed surfaces, and fraying. Correct alternator belt tension is maintained by a
belt tensioner assembly.
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.
a - 100 amp fusible link
29695
Alternator System Circuitry Test

1. Check the belt condition and tension.
2. Check wire connections at the alternator for tightness and corrosion.
3. Check the alternator ground wire for tightness at the alternator and cylinder block.
4. Check wire connections at the battery for tightness and corrosion.
5. Check the battery condition. The battery should be fully charged.
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.
Page 2B-16 90-8M0047659 JULY 2010

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 - Alternator output stud

b - Alternator ground
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 - Sensing circuit red lead

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.
90-8M0047659 JULY 2010 Page 2B-17

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 - Excitation circuit purple lead

a b
29700
Alternator Removal
! WARNING
1. Disconnect the battery cables from the batteries.

2. Disconnect the excitation/sensing wire connector from the alternator.
3. Pull the protection boot off the alternator output stud and remove the nut securing the fusible link to the alternator. Remove
the fusible link from the alternator.
a - Excitation/sensing wire connector

b - Protection boot
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.
Page 2B-18 90-8M0047659 JULY 2010

6. Remove the screw securing the alternator to the mounting bracket and remove the alternator.
a - Screw securing the alternator and ground wire

b - Screw
a
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.
a - Screw securing the alternator and ground wire

b - Screw
a
29708

7 Loctite 271 Threadlocker Alternator mounting screw threads 92-809819
25 Liquid Neoprene Alternator ground screw and ring terminal 92- 25711 3

Screw (M10 x 50) (2) 47.5 35
90-8M0047659 JULY 2010 Page 2B-19

7. Use a breaker bar to move the alternator belt tensioner assembly and install the alternator belt.
a - Breaker bar
b - Belt tensioner assembly
29705
8. Connect the excitation/sensing wire connector to the alternator.

9. Install the fusible link to the alternator output stud.
10. Secure the fusible link to the alternator with a M6 locknut. Tighten the locknut to the specified torque. Cover the alternator
output stud with the protection boot.
a - Excitation/sensing wire connector

b - Protection boot
29704

Locknut (M6) 5.6 50
Starter System
Starter Motor Amp Draw
Starter Motor Amp Draw
No load amp draw 65 amp
Normal amp draw 200 amp
Starting System Components

Battery
Key switch
Neutral start switch
Power stud
Start solenoid
Starter solenoid
Starter motor
Page 2B-20 90-8M0047659 JULY 2010

Starter System Description

The battery supplies voltage to activate the starter motor from the start solenoid. When the ignition key switch is turned to the
"START" position, the start solenoid is energized. The start solenoid completes the circuit between the battery and the starter
solenoid. The starter solenoid transfers the battery voltage to the starter motor brushes which enable the starter motor to rotate
the engine to initiate the intake, compression, combustion, and exhaust sequence. The starter motor is capable of rotating the
engine 320 RPM's.
There are two starter solenoid coil windings. The first starter solenoid coil winding pulls the starter solenoid plunger in, engaging
the gear/clutch assembly into the flywheel ring gear. The first coil winding may draw up to 40 amps at 12.6 volts when activated.
When the starter solenoid plunger is completely pulled into the starter solenoid, the first starter solenoid coil winding is
disconnected. The second starter solenoid coil winding is then activated to hold the starter solenoid plunger in, completing the
circuit to transfer battery voltage to the starter motor brushes. The second starter solenoid coil winding may draw up to 10 amps
at 12.6 volts when activated.
The neutral start switch opens the key switch start solenoid circuit when the shift control lever is not in neutral, preventing accidental
starting when the engine is in gear.
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.

BLK Black BLU Blue
BRN Brown GRY Gray
RED Red TAN Tan
Starter Circuit Troubleshooting

Before troubleshooting the starter circuit, verify the following conditions:
1. Confirm the battery is fully charged.
2. Ensure the remote control lever or tiller handle shift control is in neutral.
3. Check all power and ground terminals for corrosion or loose connections.
4. Check all cables and wiring for frayed or worn insulation.
5. Check all of the fuses related to the operation of the engine.
Use the DMT 2004 digital multimeter or an equivalent auto range digital meter for all of the tests.
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.
90-8M0047659 JULY 2010 Page 2B-21

BLK
Page 2B-22
7 8 4 3
b
c
10 f
5 d
T12
YEL/RED
a 6
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
90-8M0047659 JULY 2010

WHT 29916
T16
BRN/WHT
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
Starter Motor Does Not Turn

Test Number Procedure Test Results
A good battery voltage should be 12.6 volts or higher. Battery
Set the meter to read voltage, auto range. Measure
voltage less than 12.6 volts: check the condition of the battery
the voltage between the starting battery terminals.
and load test the battery.
Voltage reading should be the same as the battery. Voltage
reading less than the battery:
Ensure the battery positive and negative cables are the
Measure the battery voltage between test point 1 correct wire gauge for the cable length.
(power stud) and a common powerhead ground. Ensure the battery cable connections are tight on the
battery and on the powerhead.
Ensure the battery cables are not corroded.
Test 1 Voltage reading should be the same as test point 1. Voltage

reading less than test point 1:
Measure the battery voltage between test point 2 Ensure the nuts are torqued to specifications at test
(start solenoid) and a common powerhead ground. points 2 and 3.
Ensure the cable connection is not corroded.
Voltage reading should be the same as test point 2. Voltage

Measure the battery voltage between test point 3
(starter solenoid battery power cable) and a Ensure the nuts are torqued to specifications at test
common powerhead ground. points 3 and 4.
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.
No battery voltage indicated Proceed to Test 3.

Disconnect the battery voltage supply cable at the starter solenoid test point 3. This will prevent the starter motor from cranking the
powerhead.
90-8M0047659 JULY 2010 Page 2B-23


No continuity There is an open circuit between the battery
negative post and the powerhead.
Set the meter to read ohms, auto scale. Connect the Check for a loose or corroded battery negative cable
Test 3 meter at test point 5, between the common connection at the powerhead and the battery.
powerhead ground and the battery negative post. Check for an open battery negative cable.
Continuity indicated Proceed to Test 4.

Battery voltage indicated:
Check the black ground wire for a poor connection to the
Set the meter to read volts, auto scale. Disconnect common powerhead ground.
the black ground wire on the start solenoid at test Reconnect the ground wire to the start solenoid and
point 6. Connect the meter between the start proceed to Test 5.
Test 4
solenoid ground wire terminal and a common
powerhead ground. Turn the key switch to the No battery voltage indicated:
"START" position.
Reconnect the ground wire to the start solenoid and
proceed to Test 5.
Battery voltage indicated Proceed to Test 6.

No battery voltage indicated:
Connect the meter at test point 8, between the start The neutral start switch is open.
Test 5 solenoid and a common powerhead ground. Turn
the key switch to the "START" position. The yellow/red wire is open between the key switch and
the start solenoid.
The key switch has failed.
Battery voltage indicated The starter solenoid does not click.

The starter solenoid is defective.
Connect the meter at test point 7, between the start The wire between the start solenoid and the starter
Test 6 solenoid and a common powerhead ground. Turn solenoid is open or corroded. Check for continuity
the key switch to the "START" position. between test points 4 and 7.

Disconnect the key switch and check for battery Key switch is defective.
Test 7 voltage at test point 11, the red wire (pin A), and a
common powerhead ground. No battery voltage indicated:
Check the 15 amp harness fuse.
Starter Will Not Stay Engaged (Chatter)

Starter solenoid holdin coil resistance is 1.2
10%.
Disconnect the yellow/red exciter wire from the starter solenoid Starter solenoid holdin coil is good. Proceed
at test point 4. Measure the resistance between the exciter to Test 2.
Test 1
terminal of the starter solenoid and the starter solenoid metal
housing. Starter solenoid holdin coil resistance is in excess
of 1.2 10%.
Starter solenoid holdin coil is defective.
Page 2B-24 90-8M0047659 JULY 2010


Starter solenoid pullin coil resistance is 0.3
10%.
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.
90-8M0047659 JULY 2010 Page 2B-25

Page 2B-26
BLK
b 6 2
e
7 c
a 3
4
9
T12
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
90-8M0047659 JULY 2010

WHT
BLK T16
29954
BRN/WHT
a- 20 amp fuse Main power relay, engine harness, power trim

b- Start solenoid
c- Starter solenoid
d- Neutral start switch (tiller handle or remote control)
e- Key switch
f- Battery

A good battery voltage should be 12.6 volts or higher.
Set the meter to read voltage, auto range. Measure
Battery voltage less than 12.6 volts: check the condition of
the voltage between the starting battery terminals.
the battery and load test the battery.
Ensure the battery positive and negative cables are the
Measure the battery voltage between test point 1 correct wire gauge for the cable length.
(start solenoid) and a common powerhead ground. Ensure the battery cable connections are tight on the
Test 1 battery and on the powerhead.

(starter solenoid) and a common powerhead ground. points 1and 2.
activation. Disconnect the crankshaft position sensor from the powerhead wire harness. This will prevent the engine from starting.
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.

powerhead.
Test 3 meter at test point 4, between the common connection at the powerhead and the battery.
powerhead ground and the battery negative post. Check for an open battery negative cable.
90-8M0047659 JULY 2010 Page 2B-27


Check the black ground wire for a poor connection to
Set the meter to read volts, auto scale. Disconnect the the common powerhead ground.
black ground wire on the start solenoid at test point 5. Reconnect the ground wire to the start solenoid and
Test 4 Connect the meter between the start solenoid ground proceed to Test 5.
wire terminal and a common powerhead ground. Turn
the key switch to the "START" position. No battery voltage indicated:
proceed to Test 5.

Test 5 solenoid and a common powerhead ground. Turn the
key switch to the "START" position. The yellow/red wire is open between the key switch and
the start solenoid.
Battery voltage indicated the starter solenoid does not

click.
Connect the meter at test point 6, between the start
Test 6 solenoid and a common powerhead ground. Turn the The wire between the start solenoid and the starter
key switch to the "START" position. solenoid is open or corroded. Check for continuity
between test points 3 and 6.

Disconnect the key switch and check for battery Key switch is defective.
Test 7 voltage at test point 10, the red wire (pin A), and a
common powerhead ground. No battery voltage indicated:
Check the 20 amp harness fuse.

10%.
Test 1
of 1.2 10%.

10%.
Test 2
of 0.3 10%.
Page 2B-28 90-8M0047659 JULY 2010

Notes:
90-8M0047659 JULY 2010 Page 2B-29

Page 2B-30
2
c
3
b BLK 9
a
6 e
5
4
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
BLK BLK RED

BLK
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
90-8M0047659 JULY 2010

a- 15 amp harness fuse

b- Start solenoid
c- Starter solenoid
d- Neutral start switch (tiller handle or remote control)
e- Key switch
f- Battery

A good battery voltage should be 12.6 volts or higher.
Set the meter to read voltage, auto range. Measure the
Battery voltage less than 12.6 volts: check the condition of
voltage between the starting battery terminals.
the battery and load test the battery.
Ensure the battery positive and negative cables are
Measure the battery voltage between test point 1 (start the correct wire gauge for the cable length.
solenoid) and a common powerhead ground. Ensure the battery cable connections are tight on the
Test 1 battery and on the powerhead.

(starter solenoid) and a common powerhead ground. points 1and 2.
activation. Disconnect the crankshaft position sensor from the powerhead wire harness. This will prevent the engine from starting.
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.

powerhead.
Test 3 meter at test point 4, between the common powerhead connection at the powerhead and the battery.
ground and the battery negative post. Check for an open battery negative cable.
90-8M0047659 JULY 2010 Page 2B-31


Check the black ground wire for a poor connection to
Set the meter to read volts, auto scale. Disconnect the the common powerhead ground.
black ground wire on the start solenoid at test point 5. Reconnect the ground wire to the start solenoid and
Test 4 Connect the meter between the start solenoid ground proceed to Test 5.
wire terminal and a common powerhead ground. Turn
the key switch to the "START" position. No battery voltage indicated:
proceed to Test 5.

Test 5 solenoid and a common powerhead ground. Turn the
key switch to the "START" position. The yellow/red wire is open between the key switch
and the start solenoid.
Battery voltage indicated the starter solenoid does not

click.
Connect the meter at test point 6, between the start
Test 6 solenoid and a common powerhead ground. Turn the The wire between the start solenoid and the starter
key switch to the "START" position. solenoid is open or corroded. Check for continuity
between test points 3 and 6.

Continuity indicated:
Confirm the remote control or tiller handle shift lever is Key switch is defective.
in neutral. Set the meter to read ohms, auto scale.
Test 7
Check for continuity between the neutral start switch No continuity indicated:
yellow/red wires.
The neutral start switch is failed.

10%.
Test 1
of 1.2 10%.

10%.
Test 2
of 0.3 10%.
Page 2B-32 90-8M0047659 JULY 2010

Starter Removal
! WARNING

2. Remove the red protection boot from the solenoid. Remove the power cable from the starter solenoid.
3. Remove the yellow/red exciter wire from the starter solenoid.
4. Remove the four screws securing the starter mounting brackets. Remove the starter.
IMPORTANT: Identify the location and orientation of the starter mounting brackets prior to removing them. The starter
mounting brackets must be installed in the same location they were removed from. Failure to install the starter mounting
brackets in the same location they were removed from may cause a premature starter failure or a starter mounting bracket
failure.
a - Red protection boot

b - Yellow/red exciter wire
c - Screws securing the starter mounting brackets (4)
27101
Starter Solenoid Replacement

1. Remove the starter collars on the starter end caps.
2. Remove the screw securing the starter ground wire to the starter.
a
a - Starter collars (2)
b - Screw securing the starter ground wire
27102
90-8M0047659 JULY 2010 Page 2B-33

3. Remove the nut securing the brush wire to the starter solenoid and remove the brush wire.
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.
a - E5 Torx screws securing the starter solenoid (3)
27104
Starter Solenoid Installation

1. Push the starter solenoid actuating plunger into the starter solenoid. When released, the starter solenoid actuating plunger
should return to a fully extended position.
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.
b a - Fork of the solenoid arm

b - Starter solenoid actuating plunger
23485

95 2-4-C with Teflon Starter solenoid plunger 92-802859A 1
Page 2B-34 90-8M0047659 JULY 2010

4. Secure the starter solenoid to the starter with three E5 Torx screws. Tighten the screws to the specified torque.
a - E5 Torx screws securing the starter solenoid (3)
27104

E5 Torx screws securing the starter solenoid (3) 4.5 40
5. Install the brush wire onto the starter solenoid stud.

6. Secure the brush wire to the starter solenoid with a nut. Tighten the nut to the specified torque.
7. Apply Liquid Neoprene to the brush wire terminal.
a - Brush wire
b - Nut securing the brush wire
b
a
27103

Brush wire nut 6 55

25 Liquid Neoprene Starter brush wire terminals 92- 25711 3
8. Secure the starter ground wire to the starter with a screw. Tighten the screw to the specified torque. Apply Liquid Neoprene
to the starter ground wire connection.
9. Install the starter collars on the starter end caps.
a
a - Starter collars (2)
b - Screw securing the starter ground wire
27102
90-8M0047659 JULY 2010 Page 2B-35


Screw 9 80

25 Liquid Neoprene Starter ground wire screw 92- 25711 3
Starter Motor Pinion Gear Replacement

1. Remove the snap ring securing the starter motor pinion gear to the planetary gear and clutch assembly.
2. Remove the pinion gear from the planetary gear and clutch assembly.
a - Snap ring
b - Pinion gear
a b
27105
Starter Motor Pinion Gear Installation

1. Ensure the planetary gear and clutch assembly shaft splines are clear of debris. Use a razor blade to clear debris from the
root area of the shaft splines.
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
Page 2B-36 90-8M0047659 JULY 2010

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.
90-8M0047659 JULY 2010 Page 2B-37

11. Apply Liquid Neoprene to the starter power cable nut. Allow the Liquid Neoprene to dry and slide the protection boot over the
starter solenoid power cable connection.
a - Red protection boot

b - Yellow/red exciter wire
c - Screws securing the starter mounting brackets (4)
27101

Starter mounting bracket screws (4) 18 159.3
Nut securing the starter power cable 10 88.5
Nut securing the starter exciter wire 2.2 22

25 Liquid Neoprene Starter ground and solenoid terminals 92- 25711 3
Key Switch Test

Three Position Key Switch
c b a a- Pin A
b- Pin B
c- Pin C
d- Pin D
e- Pin E
f- Pin F
d e f 18868
Ref. No. Pin Wire Color Description

a A Red 12 volts
b B Black Ground
c, d C, D Purple Run
e E Black/yellow Off
f F Yellow/red Start
Page 2B-38 90-8M0047659 JULY 2010

Meter Test Leads

Key Position Reading ()
Red Black
Pin B Pin E Off Continuity
Pin A Pin F
Run Continuity
Pin A Pin C, D
Pin A Pin F Continuity
Pin F Pin C, D Start Continuity
Pin A Pin C, D Continuity
Four Position Key Switch
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
Ref. No. Pin Wire Color Description

a A Red 12 volts
b B Black Ground
c C Purple/white Accessory
d D Purple Run
e E Black/yellow Off
f F Yellow/red Start
Meter Test Leads

Key Position Reading ()
Red Black
Pin B Pin E Off Continuity
Pin A Pin C Accessories Continuity
Pin A Pin F
Run Continuity
Pin A Pin C
Pin A Pin F Continuity
Pin F Pin D Continuity
Start
Pin A Pin D Continuity
Pin A Pin C Continuity
90-8M0047659 JULY 2010 Page 2B-39

Notes:
Page 2B-40 90-8M0047659 JULY 2010

Timing, Synchronizing, and Adjusting
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
90-8M0047659 JULY 2010 Page 2C-1

Firing order 123
Air gap (S/N 0G5900000T178499) 5 mm (0.20 in.)
Special Tools
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
Idle Speed Adjustment (All Models)

Engine idle speed is not adjustable. The parameters affecting idle speed can be checked and monitored with the computer
diagnostic system (CDS).
Page 2C-2 90-8M0047659 JULY 2010

Throttle Linkage Adjustment

Throttle Linkage Adjustment S/N 1B227000 and Above
1. Adjust the rear mounted idle throttle 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.
b a - Thread measurement below the throttle

body bracket
b - Throttle body bracket
c c - Throttle body
27496

Nut (2) 7.3 65
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.
a - Thread measurement below the throttle body

bracket
27498

Nut (2) 7.3 65
90-8M0047659 JULY 2010 Page 2C-3

3. Ensure the throttle cable ends are correctly installed onto the throttle cam.
a - Throttle WOT cable

b - Throttle idle cable
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
c - Nut
a
27511

Nut 7.3 65
10. Pull on the throttle WOT cable to remove the slack.

12. Thread the bottom nut to secure the throttle WOT cable to the cable bracket. Tighten the bottom nut to the specified torque.
b a - Throttle lever stop

b - Nut
c c - Throttle WOT cable
a 27512

Nut 7.3 65
13. Loosen the WOT stop adjustment screw.
Page 2C-4 90-8M0047659 JULY 2010

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.).
a a - Throttle shutter arm clearance 0.5081.016 mm (0.020.04 in.)
27515
17. Tighten the WOT stop adjustment screw nut securely.
90-8M0047659 JULY 2010 Page 2C-5

Throttle Linkage Adjustment S/N 0T8010001B226999

IMPORTANT: The throttle cam end of the throttle cables should not, under normal service conditions, require adjustment. However,
prior to making any adjustments to the throttle linkage, verify that each of the throttle cable ends extend a distance of 11.1 1.0 mm
(0.44 0.04 in.) below the bracket. Adjust the throttle cables accordingly and torque the jam nuts to specification.
a
b
9863
a - Attaching plate
b - Jam nuts
c - 11.1 1.0 mm (0.44 0.04 in.)

Jam nuts 7.3 65
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.
Page 2C-6 90-8M0047659 JULY 2010

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
90-8M0047659 JULY 2010 Page 2C-7

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.
a - Throttle shutter opening 0.40 mm

(0.016 in.)
b
b - Throttle shutter stop screw
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.
Page 2C-8 90-8M0047659 JULY 2010

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
90-8M0047659 JULY 2010 Page 2C-9

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
a- WOT stop screw

b- WOT throttle stop
c- Throttle arm
d- Throttle shutter arm
e- Throttle shutter stop
f- Gap 0.5081.016 mm (0.020.04 in.)
Page 2C-10 90-8M0047659 JULY 2010

Fuel Pump
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
90-8M0047659 JULY 2010 Page 3A-1

Fuel Pump


Fuel Pump Description/Operation

The fuel pump is a crankcasepressureoperated, diaphragmtype pump. Crankcase pulsating pressure (created by the
upanddown movement of the piston) is transferred to the fuel pump by way of a passage (hole) between the crankcase and fuel
pump.
When the piston is in an upward motion, a vacuum is created in the crankcase, thus pulling in on the fuel pump diaphragm. The
inlet check valve (in fuel pump) is opened and fuel (from fuel tank) is drawn into the fuel pump.
Downward motion of the piston forces the mixture out of the crankcase into the cylinder. This motion also forces out on the fuel
pump diaphragm, which, in turn, closes the inlet check valve (to keep fuel from returning to the fuel tank) and opens the outlet
check valve, thus forcing fuel to the vapor separator tank (VST).
Checking for Restricted Fuel Flow Caused by AntiSiphon Valves

Antisiphon valves may clog with debris, may be too small, or may have too heavy a spring. The pressure drop across the valve
can create operational problems and/or powerhead damage by restricting fuel to the fuel pump. Symptoms of restricted fuel flow
which could be caused by an antisiphon valve are:
Loss of fuel pump pressure
Loss of power
High speed surging
Preignition/detonation (piston dome erosion)
Outboard cuts out or hesitates upon acceleration
Outboard runs rough
Outboard quits and cannot be restarted
Outboard will not start
Vapor lock
An antisiphon valve must be located between the outboard fuel inlet and the fuel tank outlet. A simple method of checking if the
valve or bad fuel is the problem, is to operate the outboard with a remote fuel tank.
If the antisiphon valve is the cause of the problem; 1) replace the antisiphon valve with one that has lighter spring tension, or 2)
replace it with a solenoidoperated fuel shutoff valve.
Page 3A-2 90-8M0047659 JULY 2010

Fuel Pump
Checking Fuel Pump Vacuum

Fuel supply restrictions/vacuum levels must not exceed specifications. High restrictions may stall the engine at low speeds, or
create a lean fuel condition at high speeds.
Mercury Marine recommends checking the fuel system vacuum on all new engines being prepared for delivery to ensure customer
satisfaction and engine durability.
The square fuel pump is designed to lift fuel vertically about 1.5 m (60 in.) if there are no other restrictions in the system, using a
fuel hose that is 8 mm (5/16 in.) minimum inside diameter. As restrictions are added, such as filters, fittings, valves, etc., the
amount of fuel pump lift decreases.
1. Fuel pump vacuum and air bubbles in the fuel supply can be checked with a vacuum gauge, a Tfitting, and a clear piece of
fuel hose.
2. Remove the pulse pump inlet hose.
3. Connect an extra, clear hose to the pulse pump.
4. Connect a Tfitting to the extra hose.
5. Connect a vacuum gauge (obtain locally) to the Tfitting.
6. Reconnect the fuel inlet hose to the remaining connection on the Tfitting.
5 6 7
8
a - Clear hose
4
3 9 c b - Tfitting
2 10 c - Vacuum gauge
1 11
0
b
a
8271
Testing Fuel Pump

Install a clear fuel hose between the fuel pump and the vapor separator tank (VST). Run the engine and inspect the clear fuel
hose for air bubbles.
Problem: Air Bubbles in Fuel Line

Low fuel in tank. Fill tank with fuel.
Loose fuel line connection. Check and tighten all connectors.
Fuel pump fitting loose. Tighten fitting.
A hole or cut in fuel line. Check condition of all fuel lines and replace.
Fuel pump anchor screw loose. Tighten all screws evenly and securely.
Fuel pump filter cover anchor screw loose. Tighten screws securely.
Fuel pump filter gasket worn out. Replace gasket.
Fuel pump gasket worn out. Rebuild fuel pump.
Fuel with high reed vapor pressure (winter grade fuel) may vaporize (form
Fuel vaporizing. bubbles) when used in hot/warm weather. Use fuel with a lower reed vapor
pressure (summer grade fuel).
Problem: Lack of Fuel Pump Pressure
An antisiphon valve. Checking for restricted fuel flow.
90-8M0047659 JULY 2010 Page 3A-3

Fuel Pump
Air in fuel line. Refer to Air Bubbles in Fuel Line.

A dirty or clogged fuel filter. Clean or replace fuel filter.
The fuel pickup in fuel tank is clogged or dirty. Clean or replace pickup.
Worn out fuel pump diaphragm. Rebuild fuel pump.
Worn out check valve in fuel pump. Rebuild fuel pump.
A leaky check valve gasket. Rebuild fuel pump.
Pulse hole plugged. Remove fuel pump and clean out holes.
Hole in pulse hose. Replace pulse hose.
Loose pulse hose. Tighten connection.
Fuel hose internal diameter too small. Use 5/16 I.D. fuel hose.
Primer bulb check valve not opening. Replace primer bulb.
Excessive fuel lift required. Fuel lift exceeds 2.5 in. of vacuum (mercury).
Vacuum Test Troubleshooting

This test is normally performed at idle speed. As engine RPM increases, there will be a slight increase in vacuum. The increase
should not exceed specification.
Normal Reading Below 2.5 in. of mercury
Restriction within the fuel system

Restricted antisiphon valve
Restriction within the primer bulb
Kinked or collapsed fuel hose
Reading above 2.5 in. of mercury Plugged water separating fuel filter (in the boat)
Restriction in fuel line throughthehull fitting
Restriction in fuel tank switching valves
Plugged fuel tank pickup screen
Fuel Pump Removal/Disassembly/Reassembly and Installation

Removal
1. Disconnect the fuel delivery line from the engine.
2. Disconnect the pulse hoses.
3. Remove the two screws securing the fuel pump to the VST.
a- Screw securing the fuel pump (2)

b- Pulse hoses
c- Fuel delivery line
d- Fuel pump
b
a
d
b
c
27111
Page 3A-4 90-8M0047659 JULY 2010

Fuel Pump
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
Cleaning and Inspection

1. Clean the fuel pump housing, check valve body, and the pump base with a solvent. Dry with compressed air.
2. Inspect the boost springs for weakness or breakage.
3. Inspect the fuel pump housing, check valve body, and the pump base for cracks or a rough gasket surface. Replace the fuel
pump assembly if these conditions are found.
4. Inspect the fittings on the fuel pump housing. Tighten the fitting if suspected of leaking.
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
90-8M0047659 JULY 2010 Page 3A-5

Fuel Pump
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
Page 3A-6 90-8M0047659 JULY 2010

Fuel Pump
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

Screws 6.8 60
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.
90-8M0047659 JULY 2010 Page 3A-7

Fuel Pump
4. Prime the system and inspect for fuel leaks.
a- Screw securing the fuel pump (2)

b- Pulse hoses
c- Fuel delivery line
d- Fuel pump
b
a
d
b
c
27111

Screws 6.8 60
Page 3A-8 90-8M0047659 JULY 2010

Fuel Injection System
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
90-8M0047659 JULY 2010 Page 3B-1




Air compressor type Reciprocating piston
Air compressor output (1.14:1 ratio with engine RPM) at idle 655 kPa (95 psi)
Displacement 60 cc (3.66 cu. in.)
Cylinder bore 52.0 mm (2.0472 in.)
Cylinder bore taper (maximum) 0.025 mm (0.001 in.)
Cylinder bore out of round (maximum) 0.025 mm (0.001 in.)
Cylinder bore type Cast iron
Stroke 27.9 mm (1.100 in.)
Piston diameter 51.95 0.01 mm (2.0453 0.004 in.)
Ring end gap
Top ring 0.150.3 mm (0.00590.0118 in.)
Middle ring 0.150.3 mm (0.00590.0118 in.)
Bottom ring 0.10.35 mm (0.00390.014 in.)
Page 3B-2 90-8M0047659 JULY 2010


Belt tensioner pulley screw threads
Tensioner retaining screw threads
Pin threads
Threads of screws securing the air compressor pulley
7 Loctite 271 Threadlocker 92-809819
Threads of the screws securing the rear seal
Throttle body bracket screw and throttle cam screw threads
Throttle position sensor screw threads
Reed block screw threads
Loctite 567 PST Pipe Air compressor elbow threads, inlet fitting threads
9 92-809822
Sealant Threads of the oil return line check valves
Air compressor cylinder bore, air compressor piston, air
compressor connecting rod bearings, air compressor crankshaft
bearings
Seals and O-rings
Electric fuel pump O-rings, fuel pump electrical harness grommet
2-Cycle Premium Outboard O-rings
14
Fuel pump elbow O-rings 92-858021K01
Oil
Direct injector O-rings
Air compressor piston, rings, and cylinder bore
Air compressor end cap O-ring and journal
Temperature sensor O-ring
Temperature sensor O-ring
25 Liquid Neoprene Ground screws 92- 25711 3
Manifold absolute pressure sensor seal
36 P80 Rubber Lubricant Obtain Locally
Water sensor O-ring
Tensioner bushings
81 Anti-Seize Compound 92-881091K 1
Tensioner spring
Fuel/water separator filter O-rings
Air pressure regulator screw threads
95 2-4-C with Teflon Fuel pressure regulator diaphragm outside circumference and the 92-802859A 1
fuel pressure regulator O-ring
Fuel injector O-rings and screw threads
4-Stroke 10W-30 Outboard
110 Air injector seals and cupped washer 92-858045K01
Oil
Special Tools
Digital Pressure Meter 91892651A01
Connects to the fuel system/manifold and can be used in conjunction with

Computer Diagnostic System (CDS).
5786
90-8M0047659 JULY 2010 Page 3B-3

Dual Fuel/Air Pressure Gauge Kit 91881834A 1
Tests fuel and air pressure; the dual gauges allow the viewing of both pressures
simultaneously.
5822
24896
Hose Clamp Tool Kit 91803146A04
Aids in the installation of high pressure (Oetiker ) hose clamps.
5819
Air Regulator Installation Tool 91889431
Compresses the air regulator spring to allow installation of assembly screws.
8291

V Hz
H z TEMP
mA
mV IG
OFF IP
TEMP
A mA COM V Hz
4516
Direct Injector Removal Tool 91883521
Aids in the removal of direct injectors from the fuel rail.
8290
Page 3B-4 90-8M0047659 JULY 2010

Leakage Tester Kit FT8950
Checks gear housing for leakage prior to filling with gear lubricant. Also used to
pressurize the oil injection system.
29497
Dial Indicator 9158222A1
Used to obtain a variety of measurements including gear backlash, pinion gear

location, and TDC.
9479
Seal/Teflon Ring Installation Tool 918519803
Aids in the installation of Teflon seals on direct injectors.

8285
Seal/Teflon Ring Sizing Tool 918519802
Compresses the Teflon seal on direct injectors after seal installation.

8286
TamperProof Screw Torx Bit Set 91881828
Aids in the removal of tamperproof fasteners.
11782
90-8M0047659 JULY 2010 Page 3B-5

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
Page 3B-6 90-8M0047659 JULY 2010


Torque
2 1 Retainer
3 4 Screw 11.3 100
4 1 Grommet
5 1 Grommet
6 1 Clamp (75.5 mm)
7 1 Screw
8 1 Washer
9 1 Washer
10 1 Bushing
13 1 Lockwasher
14 1 Spool washer
15 1 Cupped washer
17 1 Insert (75 HP) (90 HP)
18 1 Bracket
19 1 Screw (M6 x 16) 11.9 105
20 2 Cable
21 1 Cam
22 1 Bushing
23 1 Washer
24 1 Screw (M6 x 40) 10.7 95
25 1 Coupler
27 2 Screw 2.7 24
28 2 Conduit
29 1 Clamp (75.5 mm)
90-8M0047659 JULY 2010 Page 3B-7

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
Page 3B-8 90-8M0047659 JULY 2010


Torque
2 1 Retainer
3 4 Screw 11.3 100
4 1 Grommet
5 1 Grommet
6 1 Clamp
7 1 Screw
8 1 Spool washer
9 1 Cupped washer
10 1 Bushing
13 1 Lockwasher
14 1 Spool washer
15 1 Cupped washer
17 1 Roller
18 1 Bracket
19 3 Screw (M6 x 16) 11.9 105
20 2 Cable
21 1 Cam
22 1 Bushing
23 1 Washer
24 1 Screw (M6 x 40) 10.7 95
25 1 Coupler
27 3 Screw 2.7 24
28 1 Insert (75 HP) (90 HP)
29 1 Clamp (75.5 mm)
30 2 Conduit
90-8M0047659 JULY 2010 Page 3B-9

Air Hoses
5
6
1679
Page 3B-10 90-8M0047659 JULY 2010

Air Hoses
Torque
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
90-8M0047659 JULY 2010 Page 3B-11

Air Compressor Components

26 34
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
Page 3B-12 90-8M0047659 JULY 2010

Air Compressor Components

Torque
Ref. No. Qty. Description Nm lbin. lbft.
1 1 Air compressor
2 1 End cap
3 1 Oring
4 1 Connecting rod
5 1 Piston assembly
6 2 Lockring
7 1 Reed plate assembly
8 1 Gasket
9 1 Gasket
10 1 Compressor head
11 1 Fitting (45 elbow)
12 4 Screw (M8 x 35) 27.1 20
13 2 Elbow (90)
14 1 Fitting 33.9 25
15 1 Oring
16 1 Temperature sensor 17.6 13
17 1 Oring
18 3 Check valve 6.6 58
19 1 Pin 5.1 45
20 1 Fitting
21 5 Cable tie
22 1 Hose
23 1 Connector
24 1 Screw (M6 x 20) 11.3 100
25 1 Pulley
26 3 Screw (M6 x 12) 19.2 170
27 1 Tensioner arm
28 1 Pulley
29 1 Screw (M10 x 25) 25.4 18.8
30 2 Bearing (flanged)
31 2 Bushing
32 2 Tubing
33 1 Spring
34 1 Screw (M10 x 60) 22.6 16.7
35 1 Tubing
36 1 Cable tie
37 6 Screw (M8 x 90) 24.4 18
90-8M0047659 JULY 2010 Page 3B-13


Air compressor cylinder bore, air compressor piston, air
2-Cycle Premium Outboard
14 compressor connecting rod bearings, air compressor crankshaft 92-858021K01
Oil
bearings
Page 3B-14 90-8M0047659 JULY 2010

Notes:
90-8M0047659 JULY 2010 Page 3B-15

Vapor Separator Components S/N 1B417702 and Above

6
10
8
7
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
Page 3B-16 90-8M0047659 JULY 2010

Vapor Separator Components S/N 1B417702 and Above

Torque
1 1 Cover kit
2 1 Seat
3 1 Baffle
4 2 Screw (M6 x 16) 2.5 22
5 1 Gasket
6 1 Fitting 8.5 75
7 1 Oring
8 1 Fitting 5.5 50
9 1 Plug 5.1 45
10 1 Fuel filter
11 1 Float kit
12 1 Shaft
13 1 Fuel pump (highpressure)
14 1 Sleeve
15 1 Oring
16 1 Seal
17 1 Retainer
18 11 Screw 4.5 40
19 1 Boost pump
20 1 Grommet
21 1 Oring
22 1 Seal
23 1 Bowl kit
24 1 Wire
25 1 Check valve
26 2 Fitting
27 1 Inlet valve kit
28 2 Drain screw 1.7 15
29 1 Cable tie
30 1 Water sensor
31 1 Fitting
32 2 Oring
33 1 Insert
90-8M0047659 JULY 2010 Page 3B-17

Vapor Separator Components S/N 1B417701 and Below

6
10
8
7
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
Page 3B-18 90-8M0047659 JULY 2010

Vapor Separator Components S/N 1B417701 and Below

Torque
1 Vapor separator assembly
1 1 Cover kit
2 1 Seat
3 1 Baffle
4 2 Screw (M6 x 16) 2.5 22
5 1 Gasket
6 1 Fitting 8.5 75
7 1 Oring
8 1 Fitting 5.5 50
9 1 Plug 5.1 45
10 1 Fuel filter
11 1 Float kit
12 1 Shaft
13 1 Fuel pump (highpressure)
14 1 Sleeve
15 1 Oring
16 1 Seal
17 1 Retainer
18 11 Screw 4.5 40
19 1 Boost pump
20 1 Grommet
21 1 Oring
22 1 Seal
23 1 Bowl kit
24 1 Wire
25 1 Check valve
26 2 Fitting
27 1 Inlet valve kit
29 2 Oring
30 1 Water sensor
31 1 Fitting
32 2 Oring
33 1 Insert
90-8M0047659 JULY 2010 Page 3B-19

Reed Block Components

3
1 2
7
6
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
Page 3B-20 90-8M0047659 JULY 2010

Reed Block Components

Torque
1 1 Shift rail
2 2 Tab washer
3 2 Screw (M8 x 25) 24.4 18
4 1 Slide
5 1 Nut (M6)
6 1 Washer
7 1 Nut (M6) Tighten securely, then back off 1/4 turn
8 1 Gasket
9 1 Lower end cap assembly
10 1 Check valve
11 1 Oil seal
12 1 Oring
13 3 Screw (M10 x 25) 24.4 18
14 1 Reed adapter plate
15 1 Gasket
16 1 Fitting
17 1 Cover
18 1 Gasket
19 9 Screw (M8 x 45) 24.4 18
20 15 Screw (M8 x 35) 24.4 18
21 3 Reed block
22 3 Gasket
23 6 Screw (M6 x 20) 10.2 90
24 1 Manifold absolute pressure sensor
25 1 Bracket
26 1 Screw (M6 x 16) 10.2 90
27 1 Temperature sensor 1.4 13
28 1 Oring
29 1 Battery cable
30 2 Screw (M8 x 14) 24.4 18
31 2 Washer
32 1 Clamp
33 1 Washer

2-cycle Premium Outboard
14 Seals and O-rings 92-858021K01
Oil
25 Liquid Neoprene Ground screws 92- 25711 3
36 P80 Rubber Lubricant Manifold absolute pressure sensor seal Obtain Locally
90-8M0047659 JULY 2010 Page 3B-21

Fuel System Hoses
3
1
2
13
2
2 12 6 5
8
15
7
4
11
2
10 14
9
1672
Page 3B-22 90-8M0047659 JULY 2010

Fuel System Hoses

Torque
1 1 Hose
2 AR Cable tie
3 1 Hose assembly
4 1 Hose assembly
5 1 Schrader valve
6 1 Oring
7 1 Clip
8 1 Screw (M6 x 12) 10.2 90
9 1 Tubing
10 1 Fitting
11 1 Tubing
12 1 Tubing
13 1 Clamp (15.3 mm)
14 1 Hose
15 1 Seal
90-8M0047659 JULY 2010 Page 3B-23

Fuel Rail Components
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
Page 3B-24 90-8M0047659 JULY 2010

Fuel Rail Components

Torque
1 1 Fuel rail assembly
2 1 Plug
3 2 Oring kit
4 2 Clamp
5 18 Screw (M5 x 8) 8 70
6 1 Oring kit
7 1 Fitting
8 1 Bracket
9 3 Injector
10 1 Oring kit
11 1 Oring kit
12 3 Clamp
13 2 Schrader valve
14 2 Cap
15 4 Oring kit
16 2 Clamp
17 1 Elbow (90)
18 1 Plug
19 1 Oring
20 1 Oring
21 2 Clamp
22 2 Oring kit
23 1 Fitting
24 1 Fitting
90-8M0047659 JULY 2010 Page 3B-25

Vapor Separator/Fuel Rail Mounting
10
6 3
7
9 4
110
2
6
8 7
1677
Page 3B-26 90-8M0047659 JULY 2010

Vapor Separator/Fuel Rail Mounting

Torque
1 2 Stud (M10 x 91)
2 2 Nut (M10) 44.7 33
Air injector (0T979999 and below)
3 3
Air injector (0T980000 and above)
4 3 Cupped washer
5 2 Spacer
Grommet (0T979999 and below)
6 3
Grommet (0T980000 and above)
7 3 Washer
8 2 Screw (M8 x 60) 24.4 18
9 1 Screw (M8 x 35) 24.4 18
10 1 Bushing

4-Stroke 10W-30 Outboard
110 Air injector seals and cupped washer 92-858045K01
Oil
90-8M0047659 JULY 2010 Page 3B-27

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).
Air Compressor System

Air inside the cowl is drawn into the compressor through an air filter mounted on the oil tank. The filter reduces compressor noise
and prevents ingestion of contaminants into the compressor. The compressor is beltdriven from a pulley mounted on the flywheel.
A springloaded idler pulley maintains the correct belt tension. The air compressor is a single cylinder component containing a
connecting rod, piston, rings, bearings, reed valves, and a crankshaft. The compressor is watercooled to lower the temperature
of the air charge. The air compressor is lubricated with engine oil directly from the oil injection pump. As the air compressor piston
moves downward inside the cylinder, air is pulled through the air filter, reed valves, and into the cylinder. When the piston changes
direction, the intake reeds close and the exhaust reeds open, allowing compressed air into the hose leading to the air/fuel rails.
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.
Page 3B-28 90-8M0047659 JULY 2010

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.
Testing Electric Fuel Pump Output Pressure

LowPressure Electric Fuel Pump (Boost Pump)
1. Install the fuel/air pressure gauge kit to the Schrader valve on the vapor separator tank (VST).
2. Turn the ignition key to the "ON" position. The fuel pressure gauge should indicate 13.79 206.8 kPa (20 30 psi).
60 80100 6080100
40 120 40 120
20 140 20 140
160 160
10043
a - Schrader valve

HighPressure Electric Fuel Pump

1. Install the fuel/air pressure gauge kit to the fuel rail pressure test port.
2. Start the engine, or crank the engine for 15 seconds with the starter motor. The fuel pressure on the gauge must be within
specifications.
90-8M0047659 JULY 2010 Page 3B-29

IMPORTANT: The air pressure within the fuel rail must reach the minimum air pressure specification to display the highpressure
fuel accurately.
a a - Fuel pressure gauge

b - Fuel rail pressure test
port
80 80
60 100 60 100
120 40 120
140 20 140
160 160
10057
HighPressure Fuel Specification

75, 90, 115 744.6 13.8 kPa (108 2 psi)

Vapor Separator Tank

Vapor Separator Tank Assembly Removal
! CAUTION
Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the
engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and
skin from pressurized fuel and vapors.
! 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.
Page 3B-30 90-8M0047659 JULY 2010

1. Install the fuel/air pressure gauge kit and relieve the fuel pressure into an appropriate container.
a- Air pressure gauge

a b b- Fuel pressure gauge
60
80
100 60
80100
c- Air pressure test valve
d- Fuel pressure test valve (design 1)
40 120 40 120
20 140 20 140
160 160
e- Fuel pressure test valve (design 2)
d
10096

2. Cut the cable tie securing the VST vent hose to the alternator bracket.
3. Place a suitable container underneath the vapor separator drain fittings.
4. Use the rubber hose to direct the fuel into a suitable container. Open the drain screw and allow the fuel to drain from the VST.
After the fuel is drained from VST, close the drain screw and reattach the hose to each drain fitting.
90-8M0047659 JULY 2010 Page 3B-31

5. Disconnect the engine harness connector from the water sensor connector.
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.
a - 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.
Page 3B-32 90-8M0047659 JULY 2010

10. Remove the three screws securing the VST to the cylinder block. Remove the VST.
b a - Fuel inlet hose to

pulse pump
b - Fuel outlet hose
(disconnect at the
fuel rail)
c - Fuel return hose
d - Screws and washers
(3)
e - Fuel pump pulse
hoses
e
d
e c
10064
Vapor Separator Tank Disassembly

1. Remove the two screws securing the fuel pump to the VST and remove the fuel pump.
a - Fuel pump
b - Screw (2)
10112
90-8M0047659 JULY 2010 Page 3B-33

2. Use the filter removal/installation tool to remove the fuel/water separator filter from the VST.
a - Fuel/water separator filter

b - Orings
c - Filter element
a
c
10116

3. Remove the water sensor from the VST. Inspect the water sensor for damage or corrosion.
a - Water sensor
b - Oring
10118
Page 3B-34 90-8M0047659 JULY 2010

4. Remove the nine screws securing the VST cover and remove the cover.
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.
a b c a - Highpressure fuel pump

b - Boost pump
c - Screws securing the boost
pump with the retainer
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
90-8M0047659 JULY 2010 Page 3B-35

Fuel Flow Director

Fuel Flow Director Components
a - Fuel director insert

a b - Seal
c c - Seal
b
10129
Fuel Flow Director Assembly View
a- Highpressure fuel pump

b- Seal
c- Fuel director insert
a
d- Check valve
e- Seal (install on fitting)
d b
e
c 10130
Vapor Separator Tank Assembly

1. Route the fuel pump electrical harness through the VST housing.
2. Insert the red wire pin into the "A" pin receptacle on the connector. Insert the black wire pin into the "B" pin receptacle on the
connector.
Page 3B-36 90-8M0047659 JULY 2010

3. Slide the pin retainer over the harness and lock the pin retainer into the connector.
d
c
b
e
a
AB
f
10141
a- "A" pin receptacle

b- Pin retainer
c- Red wire
d- Black wire
e- "B" pin receptacle
f- Connector
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

2-Cycle Premium Electric fuel pump O-rings, fuel pump electrical harness
14 92-858021K01
Outboard Oil grommet O-rings
90-8M0047659 JULY 2010 Page 3B-37

6. Install both fuel pumps into the VST. Secure the boost pump with a retainer and two screws. Tighten the screws to the specified
torque.
a b a- Screw (2)
c b- Boost pump
c- Highpressure pump
d- Retainer
d 10122

Screw (2) 4.2 37
7. Apply P80 Rubber Lubricant to the water sensor Oring. Tighten the water sensor to the specified torque.
a - Water sensor
b - Oring
10118

36 P80 Rubber Lubricant Water sensor O-ring Obtain Locally

Water sensor 2.3 20
8. Apply 2Cycle Premium Outboard Oil to the fuel pump elbow Orings.

2-Cycle Premium
14 Fuel pump elbow O-rings 92-858021K01
Outboard Oil
Page 3B-38 90-8M0047659 JULY 2010

9. Align the gasket between the fuel pump and the VST. Secure the fuel pump to the VST with two M6 x 50 screws. Tighten the
screws to the specified torque.
a- Elbow
b- Fuel pump
c- Assembly screws
a d- Attaching screws
e- Gasket (hidden)
c
b
e
d
10137

Screw (2) 6.8 60
10. Install the needle onto the float arm.
11. Install the float onto the VST cover and secure the float pin with a screw. Tighten the screw to the specified torque.
d
a- Float
b- Needle
c- Float pin
d- Screw
c a 10120
b

Screw 1 10
12. Install the cover seal onto the VST.
27141
90-8M0047659 JULY 2010 Page 3B-39

13. Install the cover onto the VST and secure the cover to the VST with nine screws. Tighten the screws to the specified torque.
10119

Screw (9) 4.2 37
14. Apply 24C with Teflon to the fuel/water separator filter Orings. Thread the filter into the VST cover until the filter seats.
a - Fuel/water separator filter

b - Orings
c - Filter element
a
c
10116

95 2-4-C with Teflon Fuel/water separator filter O-rings 92-802859A 1
Vapor Separator Tank Assembly Installation

1. Secure the VST to the cylinder block with three screws and washers. Tighten the screws to the specified torque.
2. Install the VST vent hose to the VST. Secure the vent hose to the VST with a cable tie.
3. Install a 15.3 mm hose clamp onto the fuel outlet hose. Install the fuel outlet hose onto the VST. Crimp the hose clamp with
the hose clamp tool.
Page 3B-40 90-8M0047659 JULY 2010

4. Install the fuel return hose onto the VST. Secure the fuel return hose with a retainer and screw. Tighten the screw to the
specified torque.
5. Install the two fuel pump pulse hoses. Secure the fuel pump pulse hoses with cable ties.
6. Connect the fuel delivery hose to the pulse pump and secure with a cable tie.
7. Connect the water sensor connector to the engine harness.
c i
b
h
a
10165
f
a- Fuel delivery hose

b- Pulse hoses
c- Screw (M8 x 60) (3)
d- Fuel vent hose
e- Fuel outlet hose
f- Water sensor connector
g- Screw (M6 x 12)
h- Retainer
i- Fuel return hose

Screw (M8 x 60) 24.4 18
Screw (M6 x 12) 10.2 90
90-8M0047659 JULY 2010 Page 3B-41

8. Connect the engine harness connector to the electric fuel pump harness connector.
10058
9. Secure the VST vent hose to the alternator mounting bracket with a cable tie. Do not overtighten the cable tie.
a a - Cable tie securing the VST vent hose
27157
Page 3B-42 90-8M0047659 JULY 2010

Fuel Rail
Fuel Pressure Regulator
a - 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).
90-8M0047659 JULY 2010 Page 3B-43

Fuel Pressure Regulator Cutaway

2
1 2
1
3 3
4
4 13 5
13 5
6 12 6
12
7 7
11
8 8
11
10 10
9 9
10200
Regulator Closed Regulator Open

1 - Top cover
2 - Expansion plug
3 - Oring
4 - Spring retainer
5 - Spring
6 - Oring
7 - Diaphragm seat
8 - Air rail
9 - Air passage from air compressor
10 - Fuel return passage to vapor separator
11 - Fuel inlet passage from electric fuel pump
12 - Diaphragm assembly
13 - Calibration screw (do not adjust)
Page 3B-44 90-8M0047659 JULY 2010

Air Pressure Regulator
a - Air pressure regulator
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.
Fuel Injector Test

Prime the fuel system using the primer bulb to confirm the vapor separating tank (VST) is full.
Turn the key switch to the "ON" position. The electric fuel pumps should run for about two to three seconds.
The fuel pressure should be about 227.5296.5 kPa (3343 psi) at the fuel rail when the pumps are running.
Fuel pressure at the boost pump Schrader valve on the VST should be 137.9206.8 kPa (2030 psi).
When the pumps stop, the pressure should level off to about 68.9137.9 kPa (1020 psi) and hold.
If the pressure drops below 68.9 kPa (10 psi) quickly, it is an indication of a fuel leak.
If a fuel leak is suspected, proceed as follows:
Remove the fuel rail retainer nuts.
Remove the water outlet hose from the fuel rail.
Slide the rail away from the cylinder block and ensure the direct injectors remain in the cylinder block.
Turn the ignition key to the "ON" position to pressurize the system and look for fuel leaks at the injector openings.
90-8M0047659 JULY 2010 Page 3B-45

If fuel is leaking, check the fuel injector, the fuel injector Oring, and the fuel pressure regulator diaphragm.
a - Fuel rail pulled back from cylinder block

b - Fuel injector openings
10307
Fuel Rail Removal

! CAUTION
! WARNING
Page 3B-46 90-8M0047659 JULY 2010

2. Drain the VST into an appropriate container.

60
80
100 60
80100
40 120 40 120
20 140 20 140
160 160
d
10096

3. Remove the engine harness connectors from the fuel injectors by compressing the spring clip.
4. Remove the engine harness connectors from the direct injectors.
a - Direct injector harness

connector
b - Fuel injector harness
connector
a c - Spring clip
c
10179
90-8M0047659 JULY 2010 Page 3B-47

5. Remove the screws securing the air and fuel hose retainers.
6. Remove the fuel, water, and air hoses from the fuel rail.
NOTE: Remove the fuel hose fitting and the air hose fitting from the fuel rail. Do not cut the metal hose clamps securing the
hoses to the fittings.
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
Page 3B-48 90-8M0047659 JULY 2010

7. Remove the screw securing the fuel return hose retainer plate to the VST. Remove the fuel return hose from the VST.
b a - Screw (M6 x 12)

b - Retainer plate
27920
8. Remove the two nuts securing the fuel rail.
a - Nuts
10182
9. Use a flat tip screwdriver to ensure the direct injectors remain in the cylinder head while removing the fuel rail.
90-8M0047659 JULY 2010 Page 3B-49

NOTE: The direct injectors should remain in the cylinder head if they are not to be replaced. The direct injectors have a teflon
seal which may expand when the direct injector is removed from the head. This expansion may cause reinstallation difficulty
or require the replacement of the seal.
a - Fuel rail
b - Direct injectors
a
b
b
10183
Fuel Pressure Regulator Removal

1. Remove the four screws securing the fuel pressure regulator to the fuel rail.
2. Inspect regulator diaphragm for cuts or tears.
3. Inspect regulator housing Oring for cuts and abrasions.
e
d
c
f
a a
b 8363
a- Screws
b- Fuel pressure regulator
c- Diaphragm
d- Spring
e- Cup
f- Regulator housing Oring
Page 3B-50 90-8M0047659 JULY 2010

Air Pressure Regulator Removal

1. Remove the opposing cover screws from the air regulator cover.
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

3. Loosen the air regulator installation tool and remove the air regulator cover.
a
a - Air regulator installation tool
10223
90-8M0047659 JULY 2010 Page 3B-51

4. Inspect the regulator diaphragm for cuts or tears.
a- Screws
b- Air regulator cover
c- Diaphragm
d- Spring
e- Cup
c
d
b
e
a a
10232
Fuel Injector Removal

1. Remove the two screws securing the injector to the fuel rail.
2. Use a cotter pin extractor tool to gently pry up on the fuel injector to loosen the Oring adhesion to the fuel rail and remove
the fuel injector.
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.
Page 3B-52 90-8M0047659 JULY 2010

NOTE: The fuel injector ohm test is not polarity sensitive.
a - Fuel injector
ON
O FF
8309
Meter Test Leads

Red Black
Injector pin Injector pin Auto 1.8 0.1
Injector pin Injector steel body Auto No continuity
Direct Injector Removal

1. Remove the direct injector from the cylinder head. Use the direct injector removal tool to remove the direct injector from the
cylinder head.
a - Direct injector
b - Direct injector removal tool
a
b
10252
Direct Injector Removal Tool 91883521

2. Inspect the cup washer on the cylinder block for damage.
90-8M0047659 JULY 2010 Page 3B-53

3. If the cylinder block is to be replaced, ensure the new cylinder block supplies the cup washers. If the new cylinder block does
not have the cup washers, remove the cup washers from each direct injector port by prying it out with a flat tip screwdriver.
Reinstall the washers into the new cylinder block. The washers provide tension for the direct injectors between the cylinder
head and fuel rails.
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.
Direct Injector Tests

Direct Injector Leak Test
1. Attach the leakage tester kit to discharge side of the direct injector.
2. Pump up leakage tester to 172.4206.8 kPa (2530 psi).
3. Direct injector should not leakdown more than 3.5 kPa (1/2 psi) in one minute. Replace the direct injector if it does not meet
the specifications.
a - Leakage tester kit

b - Direct injector
b
a
15
20
10
25
5
0 30
10267
Direct Injector Ohm Test

Use the DMT 2004 digital multimeter to complete the following tests.
Page 3B-54 90-8M0047659 JULY 2010

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
Winding resistance check
Meter Test Leads

Red Black
Injector pin Injector pin Auto 1.3 0.3
2. Connect one meter lead to either injector pin and the other meter lead to the direct injector metal case. Replace the direct
injector if the resistance is out of specification.
O U .C H
ON
OFF
27185
Short to metal case check
Meter Test Leads

Red Black
Injector pin Metal case Auto 1000 or greater
90-8M0047659 JULY 2010 Page 3B-55

Direct Injector Pintel Movement Test

1. Place the direct injector into the test fixture housing.
2. Install the base plate over the direct injector. Secure the base plate with three screws. Tighten the screws to the specified
torque.
a- Test fixture housing

b- Direct injector
a c- Screw (M6 x 40)
d- Base plate
d b
c
29087

Screw (M6 x 40) 1.7 15
3. Install the nose piece into the end of the dial indicator plunger.
a
a- Dial indicator
b- Plunger
c- Nose piece
b c d- Tolerance pointers
29481
4. Connect the harness connector to the direct injector.

5. Install a 9 V battery into the battery holder.
6. Install the dial indicator into the test fixture housing. Tighten the screw to the specified torque.
7. Adjust the dial indicator bezel to point towards zero.
8. Press and release the button on the harness to actuate the direct injector.
9. Adjust the dial indicator bezel to zero if necessary.
10. Move the tolerance pointer, if equipped, to the specified limits.
11. Actuate the direct injector again.
Page 3B-56 90-8M0047659 JULY 2010

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

Screw 1.7 15
Direct Injector Specification

Direct injector pintel movement 0.0200.031 mm (0.0080.012 in.)
13. If the test result is not within specification, the direct injector is defective.
Fuel Rail Cleaning

After all components have been removed, flush the fuel rails with a solvent. Use compressed air to remove any remaining solvent.
IMPORTANT: If a mechanical failure has occurred with the air compressor or direct injector assemblies, the fuel rail must be
disassembled and flushed with a solvent to remove debris.
Air Regulator Installation

1. Secure the fuel rail in a vise to stabilize the fuel rail while installing components.
2. Position the diaphragm, spring, and cup onto the fuel rail.
a a - Cup
b b - Spring
c - Diaphragm
c
8374
90-8M0047659 JULY 2010 Page 3B-57

3. Install the cover onto the spring.

4. Install the air regulator installation tool.
a
a - Air regulator installation tool
10223

5. Compress the spring with the air regulator installation tool until the cover is seated against the fuel rail. Do not overtighten
the air regulator installation tool or damage to the regulator cover may occur.
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

95 2-4-C with Teflon Air pressure regulator screw threads 92-802859A 1
9. Install the remaining two air pressure regulator screws.
10. Tighten the four screws to the specified torque.

Screw (4) 8 70
Page 3B-58 90-8M0047659 JULY 2010

Fuel Pressure Regulator Installation

1. Apply 24C with Teflon onto the fuel pressure regulator diaphragm outside circumference and the fuel pressure regulator
Oring.

Fuel pressure regulator diaphragm outside circumference and
95 2-4-C with Teflon 92-802859A 1
the fuel pressure regulator O-ring
2. Install the fuel pressure regulator diaphragm onto the fuel rail.
3. Install the fuel pressure regulator Oring onto the fuel rail.
4. Install the fuel pressure regulator spring onto the diaphragm.
5. Install the cup onto the spring.
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
90-8M0047659 JULY 2010 Page 3B-59

7. Push the regulator cover against the fuel rail and install two of the cover retaining screws. Thread the two screws in until the
head of the screw makes contact with the cover. Do not torque the screws at this time.
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

First 5.6 50
Screws
Final 7.9 70
Fuel Injector Installation

1. Inspect the fuel injector plastic body for heat damage. Replace as needed.
2. Inspect the fuel injector nozzle for debris. Replace as needed.
3. Install new Orings onto the fuel injector.
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.
Page 3B-60 90-8M0047659 JULY 2010

6. Lubricate the fuel injector retainer screw threads with 24C with Teflon. Secure the fuel injector to the fuel rail with the retainer
and two screws. Tighten the screws to the specified torque.
b a - Injector
b - Screws
c - Retainer
a
29608

95 2-4-C with Teflon Fuel injector O-rings and screw threads 92-802859A 1

Screw 8 70
Direct Injector Installation

1. Inspect the direct injector Orings and Teflon ring for cuts or abrasions. Replace the components as necessary.
2. Use the seal/Teflon ring installation tool to slide the new seal onto the injector. Use the Teflon ring sizing tool to compress
the Teflon seal.
3. Install the direct injector into the cylinder head.
a
b c d a- Orings
b- Seal/Teflon ring installation tool
c- Teflon seal
d- Seal/Teflon ring sizing tool
27190

Fuel Rail Installation

IMPORTANT: The fuel hoses and air delivery hose must be secured to the fuel rail fittings with stainless steel hose clamps.
1. Lubricate the direct injector Orings with 2Cycle Premium Outboard Oil.

2-Cycle Premium
14 Direct injector O-rings 92-858021K01
Outboard Oil
2. Slide the fuel rail assembly over the mounting studs and onto the direct injectors.
3. Install and secure the fuel return hose onto the fuel rail.
4. Install and secure the air outlet hose onto the fuel rail.
5. Install the water hose onto the fuel rail.
6. Install the fuel inlet hose onto the fuel rail and secure with a retainer and two screws. Tighten the screws to the specified
torque.
90-8M0047659 JULY 2010 Page 3B-61

7. Install the air inlet hose onto the fuel rail and secure with a retainer and two screws. Tighten the screws to the specified torque.
b
a
c d
10181
a- Fuel hose
b- Water hose
c- Air hose
g- Air outlet hose
h- Fuel return hose

Screws 8 71
8. Secure the fuel rail to the cylinder head with two nuts. Tighten the nuts to the specified torque.
Page 3B-62 90-8M0047659 JULY 2010

9. Connect the engine harness connectors to the direct injectors.
a - Direct injector harness connector

b - Nuts
a b
10273

Nut 44.7 33
10. Connect the engine harness connectors to the fuel injectors.
11. Install the spark plug leads.
a - Spark plug leads

b - Fuel injectors
27193
90-8M0047659 JULY 2010 Page 3B-63

Air Compressor Flow Diagram

j
l
k
f m p
g
c d i
o
h
b 10294
a- Excess air return to adapter plate

b- Air muffler
c- Water outlet from fuel rail
d- Air regulator 655.0 6.9 kPa (95 1 psi)
e- Fuel regulator 751.5 6.9 kPa (109 1 psi)
f- Fuel rail
g- Fuel inlet to fuel rail 751.5 6.9 kPa (109 1 psi)
h- Excess fuel return to VST
i- Air pressure test valve (hidden)
j- Water inlet hose to air compressor
k- Highpressure air to fuel rail 655.0 6.9 kPa (95 1 psi)
l- Air compressor
m- Compressor air inlet
n- Air filter
o- Air inlet
p- Oil tank/air attenuator
Air Compressor and Fuel Pressure Tests

Air Compressor Test
1. Install the fuel/air pressure gauge kit to the fuel rail pressure test valves.
2. Supply the engine with water.
Page 3B-64 90-8M0047659 JULY 2010

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).

60
80
100 60
80100
40 120 40 120
20 140 20 140
160 160
d
10096

4. Confirm there is sufficient air volume by momentarily pinching the air discharge hose on the engine. The air pressure should
rise very quickly to 827.4 kPa (120 psi) or higher.
a - Air discharge hose pinched off to raise pressure
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
90-8M0047659 JULY 2010 Page 3B-65

Scuffed air compressor piston

Defective direct injector
Fuel Pressure Test

1. Confirm there is sufficient fuel volume by momentarily pinching the fuel return hose on the engine. The fuel pressure should
rise very quickly to 827.4 kPa (120 psi) or higher.
a - Fuel return hose pinched off to raise pressure
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.
Page 3B-66 90-8M0047659 JULY 2010

3. Remove the air compressor outlet hose from the two retainers securing the hose to the electrical plate.
a - Air compressor outlet hose

b - Screws
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.
b a - Air compressor outlet fitting

b - Cable tie securing the water outlet
c hose
c - Air inlet hose
a d - Temperature sensor
e - Cable tie securing the water inlet
hose
f - Temperature sensor connector
d
f e 27310
90-8M0047659 JULY 2010 Page 3B-67

10. Remove the six screws securing the pulley to the compressor and remove the pulley.
a - Screws securing the pulley (6)
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.
a - Screw securing the air compressor (3)

b - Cable tie securing the oil delivery line
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.
a- Cylinder #1 oil return line

b- Cylinder #2 oil return line
a c- Cylinder #3 oil return line
d- Cable tie (3)
c
d
27315
Page 3B-68 90-8M0047659 JULY 2010

Air Compressor Disassembly

1. Remove the oil return line check valves.
27331
2. Remove the screw securing the air compressor end cap to the air compressor block.
3. Remove the end cap.
a a - Screw securing the air compressor end cap

b - End cap
27332
4. Remove the inlet fitting from the air compressor head.

5. Remove the pin.
6. Remove the elbows.
7. Remove the air compressor cylinder head screws.
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.
90-8M0047659 JULY 2010 Page 3B-69

NOTE: The belt tensioner is springloaded. Use caution when removing the belt tensioner screw.
27337
10. Remove the screw securing the belt tensioner pulley to the belt tensioner.
27339
Air Compressor Assembly

1. Install the belt tensioner pulley onto the belt tensioner.
2. Apply Loctite 271 Threadlocker to the threads of the M10 x 25 belt tensioner pulley screw. Secure the belt tensioner with the
screw and tighten the screw to the specified torque.
27339

7 Loctite 271 Threadlocker Belt tensioner pulley screw threads 92-809819

Belt tensioner pulley screw (M10 x 25) 25.4 18.8
3. Apply AntiSeize Compound to the belt tensioner bushings. Install the bushings into the belt tensioner.
Page 3B-70 90-8M0047659 JULY 2010

4. Insert the tensioner screw through the bushings.
a - Tensioner screw
b - Bushing (2)
c c - Belt tensioner
a b b
27356

81 Anti-Seize Compound Tensioner bushings 92-881091K 1
5. Apply AntiSeize Compound to the tensioner spring. Install the tensioner spring onto the air compressor block. Ensure the
spring end is located inside of the spring tab on the compressor block.
a a - AntiSeize Compound
b - Spring end
27358

81 Anti-Seize Compound Tensioner spring 92-881091K 1
6. Ensure the tensioner screw threads are clean of debris. Apply Loctite 271 Threadlocker to the tensioner screw threads.
7. Secure the tensioner to the air compressor block. Tighten the tensioner retaining screw to the specified torque.
27337

7 Loctite 271 Threadlocker Tensioner retaining screw threads 92-809819
90-8M0047659 JULY 2010 Page 3B-71


Screw (M10 x 60) 22.6 16.7
8. Install the rings onto the piston.
9. Lubricate the piston and rings with 2Cycle Premium Outboard Oil.
10. Ensure the piston ring end gaps do not line up. Stagger the ring end gaps so the gaps are 120 apart.
11. Lubricate the air compressor cylinder bore with 2Cycle Premium Outboard Oil.
12. Compress the piston rings with a ring compressor and install the piston into the air compressor block.
a - Piston
b - Ring compressor (obtain locally)
a b 27359

2-Cycle Premium
14 Air compressor piston, rings, and cylinder bore 92-858021K01
Outboard Oil
13. Install the Oring onto the air compressor end cap.
14. Lubricate the Oring with 2Cycle Premium Outboard Oil.
15. Lubricate the journal with 2Cycle Premium Outboard Oil.
a - Oil delivery fitting

b
b - Oring
c - Journal
c
a
27360

2-Cycle Premium
14 Air compressor end cap O-ring and journal 92-858021K01
Outboard Oil
16. Align the connecting rod end with the journal.
17. Install the end cap and secure with a M6 x 25 screw. Tighten the screw to the specified torque.
Page 3B-72 90-8M0047659 JULY 2010

18. Rotate the air compressor pulley sheave to ensure the piston reciprocates in the air compressor cylinder bore.
b a- Belt tensioner
a b- Screw
c- Oil delivery fitting
d- Air compressor pulley sheave
c
d
27361

Screw (M6 x 25) 11.3 100
19. Install the gasket onto the air compressor block.
NOTE: The air compressor gaskets are directional.
20. Install the reed plate.
21. Install the gasket onto the reed plate.
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
90-8M0047659 JULY 2010 Page 3B-73


7 Loctite 271 Threadlocker Pin threads 92-809819
9 Air compressor elbow threads, inlet fitting threads 92-809822
Sealant

Air compressor cylinder head screws (4) 27.1 20
Pin 5.1 45
26. Apply Loctite 567 PST Pipe Sealant to the threads of the oil return line check valves. Install the oil return line check valves
and tighten to the specified torque.
27331

9 Threads of the oil return line check valves 92-809822
Sealant

Oil return line check valves 6.6 58
Air Compressor Installation

1. Install the oil return lines to the air compressor check valves and secure with cable ties.
a- Cylinder #1 oil return line

b- Cylinder #2 oil return line
a c- Cylinder #3 oil return line
d- Cable tie (3)
c
d
27315
2. Install the air compressor onto the cylinder block.

3. Secure the air compressor to the cylinder block with three M8 x 90 screws. Tighten the screws to the specified torque.
Page 3B-74 90-8M0047659 JULY 2010

4. Install the oil delivery line to the air compressor and secure with a cable tie.
a - Screw securing the air compressor (3)

b - Cable tie securing the oil delivery line
27313

Screw (3) 24.4 18
5. Apply Loctite 271 Threadlocker to the threads of the six M6 x 12 screws.
6. Install the air compressor pulley and secure to the air compressor with the six screws. Tighten the screws to the specified
torque.
a - Screw securing the pulley (6)
27312

7 Loctite 271 Threadlocker Threads of screws securing the air compressor pulley 92-809819

Screw (6) 19.2 170
7. Install the water outlet hose to the air compressor fitting and secure with a cable tie.
8. Install the water inlet hose to the air compressor fitting and secure with a cable tie.
9. Lubricate the temperature sensor Oring with 2Cycle Premium Outboard Oil.
13384

2-Cycle Premium
14 Temperature sensor O-ring 92-858021K01
Outboard Oil
10. Install the temperature sensor and tighten the temperature sensor to the specified torque.
11. Connect the engine harness connector to the temperature sensor connector.
12. Install the air inlet hose onto the air compressor.
13. Install a new Oring onto the air compressor outlet fitting.
90-8M0047659 JULY 2010 Page 3B-75

14. Lubricate the Oring with 2Cycle Premium Outboard Oil and install the air compressor outlet fitting onto the air compressor.
Tighten the air compressor outlet fitting to the specified torque.
b a - Air compressor outlet fitting

b - Cable tie securing the water outlet
c hose
c - Air inlet hose
a d - Temperature sensor
e - Cable tie securing the water inlet
hose
f - Temperature sensor connector
d
f e 27310

2-Cycle Premium
14 Temperature sensor O-ring 92-858021K01
Outboard Oil

Temperature sensor 17.6 13
Air compressor outlet fitting 33.9 25
15. Route the air compressor outlet hose next to the electrical plate and secure to the electrical plate with two retainers.
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.
Page 3B-76 90-8M0047659 JULY 2010

17. Install two screws to secure the retainer plate to the fuel rail. Tighten the screws to the specified torque.
a - Air compressor outlet hose

b - Screws
b 10277

Screw 8 71
18. Use a breaker bar to move the tension pulley and install the belt.
b a - Belt
b - Tension pulley
a c - Air compressor
27308
Fuel Pressure and Air Pressure Troubleshooting Chart

Problem Corrective Action
1. Inspect air compressor air intake for blockage.
Fuel pressure and air
2. Inspect air compressor for scuffing of cylinder wall. Inspect for broken reeds and/or reed stops.
pressure are both low.
3. Air regulator Inspect diaphragm for cuts or tears on diaphragm and rail.
1. Each time the key is turned to the "RUN" position, both electric pumps should operate for two
seconds. If they do not run, check 20 amp fuse and wire connections.
2. If pumps run, but have no fuel output, check vapor separator for fuel.
3. If no fuel is present in the vapor separator, check fuel/water separator for debris. Check pulse
Fuel pressure low or fuel
fuel pump for output.
pressure drops while
running and air pressure 4. High and lowpressure pumps are on the same electrical circuit. Amperage draw for both
remains normal. combined should be 1014 amp. If amperage is low, check for insufficient fuel to pumps or an
open circuit in one or both pumps. If amperage is high, check lowpressure pump output. It should
be 137.9206.8 kPa (2030 psi). If pressure is low, replace lowpressure pump. If pressure is
correct, replace highpressure pump.
5. Fuel regulator Inspect diaphragm for cuts or tears.
90-8M0047659 JULY 2010 Page 3B-77

Problem Corrective Action

Fuel pressure high and 1. Debris blocking fuel regulator hole.
air pressure is normal. 2. Faulty pressure gauge.
1. Debris blocking air regulator passage.
Fuel and air pressure
2. Air dump hoses (rail to muffler) blocked/plugged.
higher than normal.
3. Air muffler plugged.
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.

b
b - Nuts securing the throttle cables (4)
c - 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.
a - 75.5 mm hose clamp

a
27429
Page 3B-78 90-8M0047659 JULY 2010

Throttle Body Disassembly

1. Remove the two screws securing the throttle position sensor to the throttle body bracket. Remove the throttle position sensor.
a - Screw (2)
27434
2. Remove the coupler.
a - Throttle body bracket

b - Coupler
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.
a - Screw securing the throttle body bracket (M6 x 16)

a b - Screw securing the throttle cam (M6 x 40)
27437
6. Remove the 75.5 mm hose clamp securing the front seal to the throttle body. Remove the front seal.
90-8M0047659 JULY 2010 Page 3B-79

7. Remove the four screws and retainer securing the rear seal to the throttle body. Remove the rear seal.
a - 75.5 mm hose clamp securing the front seal

b - Four screws securing the rear seal
27438
Throttle Body Assembly

1. Install the rear seal onto the throttle body. The rear seal has a locating key molded into it. Align the molded key on the rear
seal with the key on the throttle body.
2. Apply Loctite 271 Threadlocker to the threads of the four screws. Secure the rear seal to the throttle body with the retainer
and four screws. Tighten the screws to the specified torque.
3. Install a 75.5 mm hose clamp onto the front seal.
4. Install the front seal onto the throttle body. Crimp the hose clamp with the hose clamp tool.
a - 75.5 mm hose clamp securing the front seal

b - Four screws securing the rear seal
27438

7 Loctite 271 Threadlocker Threads of the screws securing the rear seal 92-809819

Screws securing the rear seal 11.3 100

5. Install the washer and bushing onto the M6 x 40 screw.
6. Install the screw with the bushing into the throttle cam.
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.
Page 3B-80 90-8M0047659 JULY 2010

9. Install the M6 x 16 screw first. Install the throttle cam assembly with the M6 x 40 screw second. Tighten the screws to the
specified torque.
a - Screw securing the throttle body bracket (M6 x 16)

a b - Screw securing the throttle cam (M6 x 40)
27437

7 Loctite 271 Threadlocker Throttle body bracket screw and throttle cam screw threads 92-809819

Screw (M6 x 16) 11.9 105
Screw (M6 x 40) 10.7 95
10. Check the roller alignment to the throttle cam. If the roller is not within the throttle cam pocket, loosen the tamperproof screw
and adjust the roller. Tighten the tamperproof screw to the specified torque.
IMPORTANT: The throttle shutter adjustment screw is preset at the factory and is secured with an epoxy coating. The throttle
shutter adjustment screw should never need adjustment.
a b a - Throttle roller tamperproof screw

b - Throttle shutter adjustment screw
c - Roller alignment
c 27487

Tamperproof screw 10 88.5
TamperProof Screw Torx Bit Set 91881828

11. Align the coupler with the throttle cam and install the coupler.
a - Throttle body bracket

b - Coupler
a b
27435
90-8M0047659 JULY 2010 Page 3B-81

12. Align the throttle position sensor with the coupler and throttle body bracket.
13. Apply Loctite 271 Threadlocker to the threads of the throttle position sensor screws.
14. Secure the throttle position sensor to the throttle body bracket with the screws. Tighten the screws to the specified torque.
a - Screw (2)
27434

7 Loctite 271 Threadlocker Throttle position sensor screw threads 92-809819

Screw (2) 2.7 24
Throttle Body Assembly Installation

1. Install a 75.5 mm hose clamp onto the throttle body seal.
2. Install the throttle body onto the plenum. Ensure the throttle body seal is in proper alignment with the plenum.
3. Secure the throttle body to the plenum. Use the hose clamp tool to crimp the hose clamp.
a - 75.5 mm hose clamp

a
27429

4. Install the throttle cables. Refer to Throttle Cable Installation for the procedures on installing and adjusting the throttle cables.

1. Install the throttle idle cable onto the rear mounting location on the throttle body bracket.
Page 3B-82 90-8M0047659 JULY 2010

2. Adjust the 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.

body bracket
c c - Throttle body
27496

Nut (2) 7.3 65
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.

bracket
27498

Nut (2) 7.3 65
90-8M0047659 JULY 2010 Page 3B-83

5. Install the throttle idle cable and the throttle WOT cable to the throttle cam.
a - Throttle idle cable

b - Throttle WOT cable
c - Throttle cam
b
c
27507

a b
27508
7. Route the throttle cables over the top of the cylinder block and secure with the throttle cable retainer clamp.
b a - Throttle idle cable

b - Throttle cable retainer clamp
27510
8. Install the throttle idle cable and throttle WOT cable onto the throttle lever.
Page 3B-84 90-8M0047659 JULY 2010

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 - Throttle lever
c 27492

10. Pull on the throttle cable to remove the slack.
c
c - Nut
a
27511

Nut 7.3 65

15. Thread the bottom nut to secure the WOT cable to the cable bracket. Tighten the bottom nut to the specified torque.

b - Nut
a 27512

Nut 7.3 65
90-8M0047659 JULY 2010 Page 3B-85

17. Pull the throttle lever to the wideopen throttle position.
a - WOT stop
b
27514
a a - Throttle shutter arm clearance
27515

21. Install the fuel pump and secure with two screws. Tighten the screws to the specified torque.
22. Connect the engine harness connector to the water sensor connector.
23. Secure the water sensor connector to the fuel hose with a cable tie. Do not collapse the fuel hose with the cable tie.
a c a - Nuts
b - Cable tie
c - Screws (2)
b
27489

Screws securing the fuel pump (2) 6.8 60
Air Plenum and Reed Blocks

Air Plenum Removal
1. Remove the manifold absolute pressure sensor from the air plenum. Refer to Section 2A - Ignition - Manifold Absolute
Pressure (MAP) Sensor.
2. Remove the 75.5 mm hose clamp securing the throttle body to the air plenum. Refer to Throttle Body Assembly.
Page 3B-86 90-8M0047659 JULY 2010

3. Remove the manifold air temperature sensor. Refer to Section 2A - Ignition - Manifold Air Temperature (MAT) Sensor.
b a - 75.5 mm hose clamp

b - MAP sensor
c - MAT sensor
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
90-8M0047659 JULY 2010 Page 3B-87

Reed Block Removal

Remove the screws securing the reed blocks to the reed plate. Remove the reed block from the reed plate.
27536
Air Plenum Installation

Reed Block Installation
1. Ensure the reed plate is clear of debris.
2. Install new reed block gaskets onto the reed plate.
3. Install the reed blocks onto the reed plate.
4. Apply Loctite 271 Threadlocker to the threads of the reed block screws.
5. Secure the reed blocks to the reed plate with two screws for each reed block. Tighten the screws to the specified torque.
27536

7 Loctite 271 Threadlocker Reed block screw threads 92-809819

Reed block screw 10.2 90
Reed Plate Installation

1. Ensure the mating surface of the reed plate and the cylinder block are clear of debris.
2. Install the throttle cable retainer clamp onto one of the reed plate screws.
3. Install a new reed plate gasket onto the reed plate and install the screw with the throttle cable retainer clamp in the top mounting
hole of the reed plate. Secure the reed plate to the cylinder block with the top reed plate screw. Do not tighten the reed plate
screw.
b a - Throttle cables
27541
Page 3B-88 90-8M0047659 JULY 2010

4. Install the remaining 14 reed plate screws.

5. Tighten the reed plate screws in sequence to the specified torque.
10
8 9
7 6
3 4
2 1
12 11 13
27532
15 14

Reed plate screw (15) 24.4 18
Air Plenum Installation

1. Ensure the mating surfaces of the air plenum and the reed plate are clear of debris.
2. Install a new gasket onto the air plenum.
3. Secure the air plenum to the cylinder block with nine screws. Tighten the nine screws in sequence to the specified torque.
4. Connect the oil line to the check valve on top of the reed plate.
9 a - Oil line
a
8 7
3
1
4
2
5 6 27543

Air plenum screw (9) (M8 x 45) 24.4 18
5. Install the manifold air temperature sensor. Refer to Section 2A - Ignition - Manifold Air Temperature (MAT) Sensor.
6. Install the throttle body assembly to the air plenum. Refer to Throttle Body Assembly.
90-8M0047659 JULY 2010 Page 3B-89

7. Install the manifold absolute pressure sensor from the air plenum. Refer to Section 2A - Ignition - Manifold Absolute
Pressure (MAP) Sensor.
b a - 75.5 mm hose clamp

b - MAP sensor
c - MAT sensor
c
27525
Page 3B-90 90-8M0047659 JULY 2010

Oil Injection
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
90-8M0047659 JULY 2010 Page 3C-1

Oil Injection
Oiling System Components
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
Page 3C-2 90-8M0047659 JULY 2010

Oil Injection
Oiling System Components

Torque
1 1 Oil line, 63.5 cm (25 in.)
2 1 Oil line, 17.8 cm (7 in.)
3 3 Oil line, 34.3 cm (13.5 in.)
4 2 Oil line, 50.8 cm (20 in.)
5 1 Tubing, 8.3 cm (3.25 in.)
6 1 Tubing, 17.8 cm (7 in.)
7 1 Oil filter
8 AR Cable tie
9 AR Cable tie
10 1 Conduit, 15.3 cm (6 in.)
11 AR Cable tie
12 1 Oil pump
13 3 Screw (M8 x 20) 24.4 18
14 2 Hose
90-8M0047659 JULY 2010 Page 3C-3

Oil Injection
Oil System Operation

Oil is stored in a reservoir on the engine. The oil pump is actuated by the PCM and distributes oil to the crankcase and air
compressor. The oil pump has seven discharge ports with an oil delivery hose attached to each discharge port. Six of the hoses
are connected to the cylinder intakes near the reed assembly. The seventh oil delivery hose is connected to the air compressor
for lubrication. The unused oil from the air compressor returns to the cylinder bores. If an optional remote oil tank is used, the
crankcase pressure forces the oil from the remote oil tank into the oil reservoir on the engine.
The PCM is programmed to increase the oil supply to the engine during the initial engine breakin period. The oil ratio is doubled
during the first 120 minutes of operation whenever the engine is under a load. At idle the oil pump is providing oil at the normal
ratio. After the engine breakin period has expired, the oil ratio returns to normal.
NOTE: If an optional remote oil tank is installed in the boat, the engine mounted oil tank must be completely filled prior to the initial
operation. The remote oil tank will not displace the air in the engine mounted oil tank.
Oil Pump Output

Use the computer diagnostic system (CDS) to activate the auto prime. The oil pump should discharge approximately 100 8 ml
(3 0.2 oz.) during the auto prime.
To check the oil pump output:
Verify the engine mounted oil reservoir is full.
Release the pressure from the remote oil tank in the boat by loosening the cap.
With the engine not running, use the CDS to activate the auto prime.
Use a ml or cc graduated container to record the amount of oil needed to fill the engine mounted oil reservoir.
Tighten the cap on the remote oil tank in the boat.
Oil Pump Removal and Installation

Oil Pump Removal
1. Disconnect the engine harness connector from the oil pump.
2. Disconnect the oil supply hoses from the oil pump.
3. Remove the three screws securing the oil pump to the bracket and remove the oil pump.
c b a - Engine harness connector

b - Screws
c - Oil pump
10319
Oil Pump Installation

1. Secure the oil pump to the bracket with three M8 x 20 screws. Tighten the screws to the specified torque.

Screw (M8 x 20) (3) 24.4 18
2. Install the oil supply hoses to the oil pump. Secure the oil supply hoses to the oil pump with cable ties.
Page 3C-4 90-8M0047659 JULY 2010

Oil Injection
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 - Oil pump discharge port for the air compressor
a
28411
3. Connect the engine harness connector to the oil pump.

4. Ensure the oil system reservoir is filled and purged. Refer to Priming the Oil Injection Pump.
Engine Oil Reservoir

Two types of oil reservoirs/air attenuators are used on the 1.5 liter OptiMax outboards. Both types have the same oil capacity with
the 115 Pro XS and 125 version having a high air flow attenuator. The standard air flow style reservoir/attenuator should not be
used on 115 Pro XS/125 engines as reduced performance will result.
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
Engine Oil Reservoir Removal

1. Disconnect the oil supply hose. Drain the oil reservoir and oil supply hose into an appropriate container.
90-8M0047659 JULY 2010 Page 3C-5

Oil Injection
2. Disconnect the engine harness connector from the low oil sensor connector.
a - Low oil sensor connector

b - Oil supply hose
a 10332
3. Disconnect the air compressor air inlet hose.

4. Remove the two screws and washers securing the oil reservoir to the powerhead. Remove the oil reservoir.
b
a - Air compressor air inlet hose
b - Screws and washers securing the oil reservoir
a
27401
Engine Oil Reservoir Installation

1. Position the oil reservoir assembly onto the engine, aligning the throttle body seal with the air intake flange.
2. Install the air compressor air inlet hose to the oil reservoir.
b
a - Oil reservoir
a b - Air compressor air inlet hose
10331
Page 3C-6 90-8M0047659 JULY 2010

Oil Injection
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

Screw 24.4 18
4. Install the oil supply line to the oil reservoir and secure with a cable tie.
5. Connect the engine harness connector to the low oil sensor connector.
a - Low oil sensor connector

b - Oil supply hose
a 10332
6. Fill the oil reservoir and prime the oil pump. Refer to Priming the Oil Injection Pump.
90-8M0047659 JULY 2010 Page 3C-7

Oil Injection
Priming the Oil Injection Pump

Before starting engine for the first time, prime the oil injection pump. Priming will remove any air that may be in the pump, oil supply
hose, or internal passages.
a - Oil injection pump

b - Oil supply hose
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
2. Turn the ignition key switch to the "ON" position.
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.
Page 3C-8 90-8M0047659 JULY 2010

Oil Injection
Oil Hose Connection

NOTE: A directional filter between the oil reservoir and oil pump traps debris before it reaches the oil pump. The arrow on the filter
identifies the direction of the oil flow and should point towards the oil pump. The replacement of the oil filter is every three years
or 300 hours. Refer to Section 1B - Maintenance - In-line Oil Filter Replacement.
a - Oil filter
10368
Optional Remote Oil Tank Installation

1. Remove the duckbill valve from the oil reservoir.
2. Install the screw where the duckbill valve was removed from the oil reservoir.
3. Remove the cable tie and cap from the 90 elbow.
a - Duckbill valve location

b - Screw
b c - Cap
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.
90-8M0047659 JULY 2010 Page 3C-9

Oil Injection
6. Secure the molded hose to the side of the oil tank with two cable ties. Do not overtighten the cable ties.
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
11. Find a suitable location for the remote oil tank.

12. Fasten the holddown bracket to the floor using the clamps.
13. Secure the remote oil tank in place with a bungy cord.
14. Attach the hoses to the remote oil tank. The bluestriped hose should be attached to the top fitting of the oil tank adapter.
Low Oil Warning System Activated

NOTE: Low oil level in the enginemounted oil tank is indicated by the warning horn beeping four times every two minutes.
Page 3C-10 90-8M0047659 JULY 2010

Oil Injection
Component or Problem Possible Causes Corrective Action

Purge air from the engine oil
Air was never purged from the engine oil reservoir by operating the engine
reservoir. with the cap removed.
Top off the tank with oil.
Inspect the remote tank cap seals.
Ensure that the cap is installed
Fill cap is leaking air on the remote tank.
tightly.
Replace components as necessary.
Inspect hoses for nicks, cuts, or
kinks.
Remote oil hose is blocked, cut, or porous. Pressure check each hose for
Low oil level in engine oil reservoir, but
internal leaks.
sufficient level in remote tank
Replace components as necessary.
Oil outlet filter in the remote oil tank is Remove, inspect, and clean the filter.
restricted. Replace if necessary.
Oil inlet filter in the oil hose before the oil
Replace oil filter.
reservoir is restricted.
Air leak in the upper portion on the oil pickup
Replace the pickup tube.
tube.
Pressure check valve is faulty (located in the
engine at the end of the remote oil hose) Replace the check valve.
(black hose, no stripe).
Hose connections. Check all hose connections for leaks.
Refill both tanks. Purge air from the
engine oil tank and the remote oil
Low oil level in engine oil reservoir and remote hose.
Lack of proper, periodic maintenance.
oil tank
Refer to the Operation Manual for
the maintenance schedule.
Perform a resistance test on the low
Low oil switch in the engine oil reservoir is
oil switch. Replace components as
faulty.
necessary.
Check the condition of the
Low oil switch in the engine reservoir is
Oil level in both tanks is OK connection and correct as
disconnected.
necessary.
Check the sensor connection for
Bad ground. proper ground. Correct as
necessary.
Pulse hose and oil supply hose are
Correct the hose orientation.
reversed.
Boat oil tank is mounted higher than the
pulse hose fitting on the engine, and the oil
Oil leaks out of exhaust or #3 cylinder Correct the oil tank installation
tank is overfilled.
location. Clean internal engine
A deck fill kit is installed. Overfilling the oil components.
tank with a deck fill kit installed may cause
this problem.
90-8M0047659 JULY 2010 Page 3C-11

Oil Injection
Notes:
Page 3C-12 90-8M0047659 JULY 2010

Emissions
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
90-8M0047659 JULY 2010 Page 3D-1

Emissions
Exhaust Emission Standards

Through the Environmental Protection Agency (EPA), the federal government has established exhaust emission standards for all
new marine engines sold in the U.S.
What Are Emissions?

Emissions are what comes out of the exhaust system in the exhaust gas when the engine is running. They are formed as a result
of the process of combustion or incomplete combustion. To understand exhaust gas emissions, remember that both air and fuel
are made of several elements. Air contains oxygen and nitrogen among other elements; gasoline contains mainly hydrogen and
carbon. These four elements combine chemically during combustion. If combustion were complete, the mixture of air and gasoline
would result in these emissions: water, carbon dioxide, and nitrogen, which are not harmful to the environment. But, combustion
is not usually complete. Also, potentially harmful gases can be formed during and after combustion.
All marine engines must reduce the emission of certain pollutants, or potentially harmful gases, in the exhaust to conform with
levels legislated by the EPA. Emission standards become more stringent each year. Standards are set primarily with regard to
three emissions: hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx).
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.
Oxides of Nitrogen NOx

NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that makes up the air going into the engine.
Under extremely high temperatures it combines with oxygen to form oxides of nitrogen (NOx). This happens in the engine's
combustion chambers when temperatures are too high. NOx itself is not harmful, but when exposed to sunlight it combines with
unburned hydrocarbons to create the visible air pollutant known as smog. Smog is a serious problem in California as well as many
other heavily populated areas of the United States.
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.
Page 3D-2 90-8M0047659 JULY 2010

Emissions
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.
EPA Emission Regulations

All new 1998 and newer outboards manufactured by Mercury Marine for operation in the USA, 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, whenever practicable, returned to the original intent of the design.
The responsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the EPA
laws on exhaust emissions for marine products. For more detailed information on this subject, you may contact the following
location:
EPA INTERNET WEB SITE: http://www.epa.gov/otaq/marinesi.htm
Manufacturer's Certification Label

The certification label must be placed on each engine at the time of manufacture and must be replaced in the same location if
damaged or removed. Shown below is a typical certification label and is not representative of any one model. Label shown below
is not to scale.
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 (if applicable)

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
Service Replacement Certification Label

IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine outboards have a visible and legible emission
certification label. If this label is missing or damaged, contact Mercury Marine Service for a replacement.
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.
90-8M0047659 JULY 2010 Page 3D-3

Emissions
Notes:
Page 3D-4 90-8M0047659 JULY 2010

Powerhead
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
90-8M0047659 JULY 2010 Page 4A-1

Powerhead
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.)
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 skirt standard diameter 91.9226 0.0127 mm (3.619 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.)
Thermostat
Water pressure
at 625 RPM (idle) 20.641.3 kPa (36 psi)
at 5750 RPM (WOT) 75.896.5 kPa (1114 psi)

Needle Bearing Assembly Connecting rod bearing
4 92-802868A 1
Lubricant Crankshaft connecting rod journals, rod bearing cages
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.
Page 4A-2 90-8M0047659 JULY 2010

Powerhead

Reed block screw threads
Screw threads securing the throttle lever
Retainer plate screw threads
Retainer plate screw threads
Loctite 567 PST Pipe Temperature sensor assembly threads
9 92-809822
Sealant Legris fitting threads and flushing hose fitting threads
12 Loctite Master Gasket Kit Mating surface of the crankcase cover 92-12564 2
Piston rings, piston, piston pin bearings, connecting rod screws,
crankshaft seal, crankshaft bearings
Cylinder bores after honing
Crankshaft journals
Lower crankshaft ball bearing
Center main bearings and upper roller bearing
Crankshaft ball bearing
Center main bearings
2-Cycle Premium Outboard O-ring
14 92-858021K01
Oil Upper crankshaft roller bearing
Piston, rings, and cylinder wall
Threads and face of the connecting rod cap screws
Cylinder bores and piston rings
Crankshaft lower seal area
Direct injector O-rings
Fuel return hose seal and O-ring
Fuel delivery hose O-rings
Air delivery hose fitting O-ring
All ground screws
Starter ground and mounting screw
Screw securing ground wire eyelet
Ground screws and straps
Ground screws, straps, and starter exciter wire terminal
Alternator ground screw
Oil seal lip
Needle bearings
95 2-4-C with Teflon 92-802859A 1
Driveshaft splines
Shift bracket
117 Loctite 7649 Primer N Mating surfaces of the crankcase cover and cylinder block 92-809824
Special Tools
Threads into the flywheel to remove the powerhead assembly from the driveshaft
housing, or to lift entire engine for removal/installation.
2756
Connects to the fuel system/manifold and can be used in conjunction with

Computer Diagnostic System (CDS).
5786
90-8M0047659 JULY 2010 Page 4A-3

Powerhead
Tests fuel and air pressure; the dual gauges allow the viewing of both pressures
simultaneously.
5822
Piston Ring Expander 9124697
Expands piston rings for removal and installation.
6255
Lockring Removal Tool 9152952T 1
Removes the lockrings securing the piston wrist pin.

8500
Piston Pin Tool 9192973A 1
Aids in the removal and installation of the piston pins.

11564
Universal Puller Plate 9137241
Removes bearings from gears and the driveshaft.
8505
Powerhead Stand 91812549T
Used to secure and rotate the powerhead during disassembly and assembly.
8493
Lockring Installation Tool 91 93004A 2
Installs the lockrings to secure the piston wrist pin in piston.

8527
Holds and/or turns the flywheel while making engine repairs, also used to torque
the flywheel or the engine coupler.
4738
Aids in the installation of Teflon seals on direct injectors.

8285
Page 4A-4 90-8M0047659 JULY 2010

Powerhead
Compresses the Teflon seal on direct injectors after seal installation.

8286
90-8M0047659 JULY 2010 Page 4A-5

Powerhead
Cylinder Block and Crankcase S/N 0T8010001B417701

33
30
27
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
Page 4A-6 90-8M0047659 JULY 2010

Powerhead
Cylinder Block and Crankcase S/N 0T8010001B417701

Torque
1 1 Cylinder block
2 1 Dowel pin
3 3 Center main pin
4 8 Screw (M10 x 80) 37.9 28
5 2 Bracket
6 4 Screw (M10 x 80) 24.4 18
7 1 Fitting (0.250 x 18) (brass)
8 3 Plug (0.375 x 18)
9 12 Screw (M8 x 35) 24.4 18
10 1 Elbow (90)
11 3 Check valve
12 3 Check valve
13 1 Elbow fitting (45)
14 1 Check valve
15 3 Water deflector
16 7 Plug (0.375 x 18)
17 1 Fitting
18 8 Stud (M10 x 136)
19 4 Washer
First 27 20
20 8 Nut (M10)
Final Turn additional 90
21 3 Check valve (90)
22 2 Seal
23 1 Plug (0.375 x 18)
24 2 Screw (M8 x 20) 24.4 18
25 1 Crankshaft position sensor
26 2 Screw (M5 x 16) 5.1 45
27 1 Flywheel cover
28 3 Grommet
29 1 Coupling insert
30 1 Coupling body
31 1 Cap
32 1 Tubing
33 AR Cable tie
34 1 Fitting
35 1 Oil reservoir bracket
90-8M0047659 JULY 2010 Page 4A-7

Powerhead
Cylinder Block and Crankcase S/N 1B417702 and Above

30 27
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
Page 4A-8 90-8M0047659 JULY 2010

Powerhead
Cylinder Block and Crankcase S/N 1B417702 and Above

Torque
1 1 Cylinder block
2 1 Dowel pin
3 3 Center main pin
4 8 Screw (M10 x 80) 37.9 28
5 2 Bracket
6 4 Screw (M10 x 80) 24.4 18
7 1 Fitting (0.250 x 18 ) (brass)
8 3 Plug (0.375 x 18)
9 12 Screw (M8 x 35) 24.4 18
10 1 Elbow (90)
11 3 Check valve
12 3 Check valve
13 1 Elbow fitting (45)
14 1 Check valve
15 3 Water deflector
16 7 Plug (0.375 x 18)
17 1 Fitting
18 8 Stud (M10 x 136)
19 4 Washer
First 27 20
20 8 Nut (M10)
21 3 Check valve (90)
22 2 Seal
23 1 Fitting
24 2 Screw (M8 x 20) 24.4 18
25 1 Crankshaft position sensor
26 2 Screw (M5 x 16) 5.1 45
27 1 Flywheel cover
28 3 Grommet
29 1 Oil reservoir bracket
30 1 Hose assembly
90-8M0047659 JULY 2010 Page 4A-9

Powerhead
14
13
25 8
12 9
10 6
15
1
11
2 3 4
5
7
11
1675
Page 4A-10 90-8M0047659 JULY 2010

Powerhead

Torque
1 1 Poppet
2 1 Diaphragm
3 1 Washer
4 1 Screw (1016 x 0.750)
5 1 Spring
6 1 Cover
7 4 Screw (M8 x 35) 24.4 18
8 1 Gasket
9 1 Gasket
10 1 Thermostat
11 2 Clamp
12 1 Screw (M6 x 12) 16.2 144
13 1 Temperature sensor assembly 15 133
14 1 Oring
15 1 Spacer

25 Liquid Neoprene All ground screws 92- 25711 3
90-8M0047659 JULY 2010 Page 4A-11

Powerhead
14
13
25 8
12 9
10 6
15
1
11
2 3 4
17 5
16
21
20 18
7
11
19 9435
Page 4A-12 90-8M0047659 JULY 2010

Powerhead

Torque
1 1 Poppet
2 1 Diaphragm
3 1 Washer
4 1 Screw (1016 x 0.750)
5 1 Spring
6 1 Cover
7 4 Screw (M8 x 35) 24.4 18
8 1 Gasket
9 1 Gasket
10 1 Thermostat
11 2 Clamp
12 1 Screw (M6 x 12) 16.2 144
13 1 Temperature sensor assembly 15 133
14 1 Oring
15 1 Spacer
16 1 Bracket assembly
17 2 Grommet
18 2 Bushing
19 2 Clip
20 2 Screw (M6 x 25) 11 98
21 2 Washer

25 Liquid Neoprene All ground screws 92- 25711 3
90-8M0047659 JULY 2010 Page 4A-13

Powerhead
Crankshaft, Pistons, and Connecting Rods
10547
Page 4A-14 90-8M0047659 JULY 2010

Powerhead
Crankshaft, Pistons, and Connecting Rods

Torque
1 1 Crankshaft assembly
2 1 Retaining ring
3 1 Ball bearing
4 1 Key
5 1 Wear sleeve
6 1 Oring
7 2 Seal ring
8 2 Bearing
9 4 Needle bearing
10 3 Piston assembly
11 3 Piston pin
12 6 Lockring
13 1 Piston ring set
14 3 Connecting rod assembly
15 6 Thrust washer
16 102 Needle bearing
First 4.5 40
17 6 Screw (0.37524 x 1.250) Second 40.6 30
18 6 Bearing assembly
19 48 Roller bearing
20 1 Roller bearing assembly
21 1 Oil seal

Needle Bearing Assembly
4 Connecting rod bearing 92-802868A 1
Lubricant
2-Cycle Premium Outboard Piston rings, piston, piston pin bearings, connecting rod screws,
14 92-858021K01
Oil crankshaft seal, crankshaft bearings
90-8M0047659 JULY 2010 Page 4A-15

Powerhead
Throttle Lever and Linkage
10661
Page 4A-16 90-8M0047659 JULY 2010

Powerhead

Torque
1 1 Throttle lever
2 1 Bumper
3 1 Bushing
4 1 Insert
5 1 Screw (M10 x 45) 27 20
6 1 Bracket lever arm assembly
7 1 Screw (M6 x 35)
8 1 Nut
9 1 Nylon cap
10 1 Screw (M6 x 16) 10.2 90
11 1 Washer
12 1 Nut
90-8M0047659 JULY 2010 Page 4A-17

Powerhead
Dressed Powerhead Removal

! WARNING
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.
Page 4A-18 90-8M0047659 JULY 2010

Powerhead
7. Remove the nut securing the shift arm to the shift slide.
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
8. Disconnect the optional remote oil tank hose connections if equipped.
a- Check valve
b- Hose with blue stripe
c- Cable tie
a d- Pressure hose
c
b c
d
10391
90-8M0047659 JULY 2010 Page 4A-19

Powerhead
9. Disconnect the engine harness from the remote control harness.
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.
a - Cowl tilt switch connector
10393
12. Remove four screws securing the cowl halves together.

13. Loosen one screw securing the front cowl halves together.
14. Remove two nuts securing the cowl halves to the driveshaft housing.
Page 4A-20 90-8M0047659 JULY 2010

Powerhead
NOTE: The telltale hose, air compressor dump hose, and vapor separator tank (VST) vent hose, pass through openings in
the cowl halves.
b
a- Screw (M6 x 40) (4)
b- Screw (M6 x 16) (1)
c- Nut (M8) (2)
a d- Idle relief boot
10394
15. Disconnect the SmartCraft harness connector.
a - SmartCraft harness connector
a
10396
16. Disconnect the blue and green trim motor harness leads.
90-8M0047659 JULY 2010 Page 4A-21

Powerhead
17. Disconnect the neutral switch harness connector from the engine harness.
a - Blue and green trim motor harness leads

b - Neutral switch harness connector
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
Page 4A-22 90-8M0047659 JULY 2010

Powerhead
19. Remove the plastic cap from the center of the flywheel and install the lifting eye into the flywheel five turns minimum. Lift the
powerhead assembly from the driveshaft housing.
a - Lifting eye
10410
Removing Engine Component Assemblies

Fuel Rail Removal
! CAUTION
! WARNING
90-8M0047659 JULY 2010 Page 4A-23

Powerhead
2. Drain the VST into an appropriate container.

60
80
100 60
80100
40 120 40 120
20 140 20 140
160 160
d
10096

3. Remove the engine harness connectors from the fuel injectors by compressing the spring clip.
4. Remove the engine harness connectors from the direct injectors.
a - Direct injector harness

connector
b - Fuel injector harness
connector
a c - Spring clip
c
10179
Page 4A-24 90-8M0047659 JULY 2010

Powerhead
5. Remove the screws securing the air and fuel hose retainers.
6. Remove the fuel, water, and air hoses from the fuel rail.
NOTE: Remove the fuel hose fitting and the air hose fitting from the fuel rail. Do not cut the metal hose clamps securing the
hoses to the fittings.
b
a
c d
10181
a- Fuel hose
b- Water hose
c- Air hose
g- Air outlet hose
h- Fuel return hose
90-8M0047659 JULY 2010 Page 4A-25

Powerhead
7. Remove the screw securing the fuel return hose retainer plate to the VST. Remove the fuel return hose from the VST.

b - Retainer plate
27920
8. Remove the two nuts securing the fuel rail.
a - Nuts
10182
9. Use a flat tip screwdriver to ensure the direct injectors remain in the cylinder head while removing the fuel rail.
Page 4A-26 90-8M0047659 JULY 2010

Powerhead
NOTE: The direct injectors should remain in the cylinder head if they are not to be replaced. The direct injectors have a teflon
seal which may expand when the direct injector is removed from the head. This expansion may cause reinstallation difficulty
or require the replacement of the seal.
a - Fuel rail
b - Direct injectors
a
b
b
10183
Vapor Separator Tank Assembly Removal

Vapor Separator Tank Assembly Removal S/N 1B417702 and Above
1. Disconnect the engine harness connector from the VST fuel pump connector.
27912
27910
3. Cut the cable ties securing the fuel pump upper and lower pulse hoses to the cylinder block fittings.
90-8M0047659 JULY 2010 Page 4A-27

Powerhead
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
Vapor Separator Tank Assembly Removal S/N 1B417701 and Below

2. Use the rubber hose connecting the drain fittings to drain the fuel into a suitable container. Open the drain screw several turns
to allow the fuel to drain from the VST. After the fuel has drained from the VST, close the drain screw and reattach the hose.
Page 4A-28 90-8M0047659 JULY 2010

Powerhead
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.
90-8M0047659 JULY 2010 Page 4A-29

Powerhead
6. Remove the three screws and washers securing the VST to the cylinder block. Remove the VST assembly.
b a - Fuel inlet hose to

pulse pump
b - Fuel outlet hose
c - Fuel return hose
d - Screws and washers
(3)
e - Fuel pump pulse
hoses
e
d
e c
10064
Air Plenum and Throttle Body Assembly Removal

1. Remove the screw and washer securing the throttle lever to the cylinder block.
2. Remove the screw securing the throttle cable bracket to the cylinder block.
a - Screw securing the throttle lever

b - Screw securing the throttle cable bracket
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.
Page 4A-30 90-8M0047659 JULY 2010

Powerhead
5. Disconnect the engine harness connector from the throttle position sensor connector.
a - MAP sensor connector

b - Throttle position sensor connector
c - Manifold air temperature sensor connector
10069
90-8M0047659 JULY 2010 Page 4A-31

Powerhead
6. Remove the nine screws securing the air plenum to the cylinder block. Remove the air plenum throttle body assembly.
a - Screw (9)
10070
Alternator Assembly Removal

1. Remove the screw securing the alternator ground to the cylinder block.
27666
2. Disconnect the exciter wire harness connector from the alternator.

3. Remove the insulating boot covering the locknut and washer securing the battery charging fusible link cable to the alternator.
Page 4A-32 90-8M0047659 JULY 2010

Powerhead
4. Remove the locknut and washer securing the battery charging fusible link cable to the alternator. Remove the battery charging
fusible link cable from the alternator.
a - Exciter wire harness connector

b - Insulating boot
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.
b a - Screw (3) and washers (6)

a b - Alternator ground
27669
Electrical Harness Assembly Removal

1. Disconnect the engine harness connector from the oil pump.
2. Remove three screws securing the oil pump to the electrical harness bracket.

b b - Screws securing the oil pump (3)
27670
3. Remove the alternator exciter wire harness and the battery charging fusible link cable from the clip on the engine.
90-8M0047659 JULY 2010 Page 4A-33

Powerhead
4. Remove the two screws securing the 14 pin harness bracket to the cylinder block.
b a - Screws securing the 14 pin harness bracket (2)

b - Clip
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 - Trim position sender wire

b - Trim motor bullet connectors
c - Shift switch 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.
Page 4A-34 90-8M0047659 JULY 2010

Powerhead
14. Remove the screw securing the battery negative cable to the cylinder block.
b a- Red insulating boot covering the starter power cable

b- Starter exciter wire
c c- Electrical plate ground wire
d d- Battery negative cable
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.
b a - Retainer securing the air hose

b - Air compressor temperature sensor
connector
a c - Crankshaft position sensor connector
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.
90-8M0047659 JULY 2010 Page 4A-35

Powerhead
21. Remove the screw securing the ground wire and electrical bracket to the cylinder block.
a a - Red insulator boot

b b - Screw and large washer
c - Screw and small washer securing the ground wire
and electrical bracket
c
27677
Starter Motor Removal

IMPORTANT: Identify the location and orientation of the starter mounting brackets prior to removing them. The starter mounting
brackets must be installed in the same location they were removed from. Failure to install the starter mounting brackets in the
same location they were removed from may cause a premature starter failure or a starter mounting bracket failure.
Remove the four screws securing the starter mounting brackets to the cylinder block and remove the starter.
a
a - Starter ground
b - Screw (4)
27665
Air Compressor Assembly Removal

1. Cut the cable tie securing the air compressor water hose to the cylinder block water strainer fitting and remove the air
compressor water hose.
2. Remove the water hose from the retainer.
3. Cut the cable tie securing the oil line to the air compressor oil check valve. Remove the oil line from the check valve.
c a - Cable tie securing the water hose

b - Retainer securing the water hose
b c - Cable tie
27679
Page 4A-36 90-8M0047659 JULY 2010

Powerhead
4. Cut the cable ties securing the air compressor oil return lines to the cylinder block and remove the oil return lines.
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
Oil Pump Assembly Removal

1. Cut the cable tie securing three oil lines to the recirculation line.
2. Cut the cable ties securing the oil lines to the 90 crankcase check valve fittings and remove the oil lines.
90-8M0047659 JULY 2010 Page 4A-37

Powerhead
3. Cut the cable ties securing the oil lines to the crankcase main bearing straight check valve fittings and remove the oil lines.
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
Flush Hose and Shift Bracket Removal

1. Remove the two screws securing the crankshaft position sensor to the cylinder block.
2. Remove the water temperature sensor from the cylinder block.
3. Remove the Legris fitting from the cylinder block.
4. Cut the cable tie securing the flushing hose to the cylinder block and remove the flushing hose.
a a- Crankshaft position sensor

b- Water temperature sensor
c- Legris fitting
b d- Cable tie securing the flushing hose
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.
Page 4A-38 90-8M0047659 JULY 2010

Powerhead
7. Remove the two screws securing 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.
a - 90 check valve fitting (3)

b - Straight check valve fitting (3)
b
a
27769
3. Remove the four 90 check valve fittings on the cylinder block.
27770
90-8M0047659 JULY 2010 Page 4A-39

Powerhead
4. Remove the four screws securing two clips and the thermostat cover to the cylinder block.
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
End Cap Removal

1. Remove the three screws securing the end cap to the cylinder block.
a - Screw (3)
10519
2. Remove the 12 perimeter screws securing the crankcase cover to the cylinder block.
Page 4A-40 90-8M0047659 JULY 2010

Powerhead
3. Remove the eight main bearing screws securing the crankcase cover to the cylinder block.
a a - Perimeter screw (12)

b - Main bearing screw (8)
a
27777
4. Remove the end cap.

5. Remove and discard the Oring from the end cap.
6. Remove the oil seals from the end cap.
b
a - Oring
b - Oil seal
10522
a
Cylinder Block Disassembly

1. Remove the crankshaft and pistons as an assembly.
10525
2. Identify the cylinder location of each connecting rod, piston, and rod cap with a marker or paint.
90-8M0047659 JULY 2010 Page 4A-41

Powerhead
IMPORTANT: Do not use a scribe or a metal punch on the connecting rod, piston, or rod cap for identification purpose. Using
a scribe or metal punch will damage the components and may cause premature engine failure.
a - Marker or paint identifying the

cylinder location
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.
a - Connecting rod screws
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.
Page 4A-42 90-8M0047659 JULY 2010

Powerhead
7. Use the piston ring expander to remove the piston rings.
a - Piston ring expander
10529

8. Use the lockring removal tool to remove the piston pin lockrings from both ends of the piston pin. Discard the piston pin
lockrings.
a
a - Lockring
b - Lockring removal tool
10530
Lockring Removal Tool 9152952T 1

9. Support the piston and tap the piston pin out with the piston pin tool.
b a - Piston pin
b - Piston pin tool
10531
Piston Pin Tool 9192973A 1
90-8M0047659 JULY 2010 Page 4A-43

Powerhead
10. Remove the piston pin needle bearings and locating washers. There are 34 piston pin needle bearings and two locating
washers per piston. Discard the piston pin needle bearings and retain the locating washers.
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.
b a - Upper crankshaft bearing

b - 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
14. Remove the crankshaft sealing rings if broken or damaged.
Page 4A-44 90-8M0047659 JULY 2010

Powerhead
IMPORTANT: Do not remove the crankshaft sealing rings from the crankshaft unless replacement of a sealing ring is
necessary.
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.
Lower Crankshaft Bearing Removal

1. Use a pair of snap ring pliers to remove the retaining ring securing the lower crankshaft bearing to the crankshaft.
b a a - Crankshaft ball bearing

b - Pliers
c - Retaining ring
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

Powerhead Stand 91812549T
90-8M0047659 JULY 2010 Page 4A-45

Powerhead
Cleaning, Inspection, and Repair

Cylinder Block and Crankcase Cover
1. Clean the cylinder block and crankcase cover mating surfaces. Ensure all of the sealant and the old gaskets are removed.
Clean the cylinder block of all carbon deposits.
2. Inspect the cylinder block and the crankcase cover for cracks or fractures.
3. Inspect the mating surfaces for nicks, deep grooves, cracks, or distortion.
4. Remove the three water dam pipe plugs. Remove the water dams and inspect for damage. Replace the water dams as
required.
NOTE: If the water dams are missing or damaged, the engine may overheat. The water dams are necessary to maintain
proper coolant flow around the cylinder bores.
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.
Page 4A-46 90-8M0047659 JULY 2010

Powerhead
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
Cylinder block finish hone

Standard 92.1131 mm (3.6265 in.)
0.38 mm (0.015 in.) oversize 92.4941 mm (3.6415 in.)
0.76 mm (0.030 in.) oversize 92.8751 mm (3.6565 in.)
7. If a cylinder bore is tapered or outofround more than 0.076 mm (0.003 in.) from the finished hone diameter, it will be necessary
to bore the cylinder oversize.
NOTE: The weight of an oversize piston is approximately the same as a standard size piston. It is not necessary to bore all
the cylinders oversize.
8. After measuring the cylinder bores, apply 2Cycle Premium Outboard Oil to the cylinder bores to prevent corrosion.

2-Cycle Premium
14 Cylinder bores after honing 92-858021K01
Outboard Oil
Pistons and Piston Rings

IMPORTANT: If the engine was submerged during operation, the piston pin and/or connecting rod may be bent. If the piston pin
is bent, replace the piston. Piston pins are not sold separately because of the matched fit into the piston. If the piston pin is bent,
check the connecting rod for straightness. Refer to Connecting Rods for information.
1. Inspect the pistons for scoring and excessive piston skirt wear.
2. Check the tightness of the piston ring locating pins. The locating pins must be tight.
3. Thoroughly clean the pistons. Carefully remove carbon deposits from the pistons with a soft wire brush or carbon removal
solution. Do not burr or round off machined edges.
4. Inspect the piston ring grooves for wear and carbon accumulation. If necessary, scrape the carbon from the piston ring grooves
being careful not to scratch the sides of the grooves.
90-8M0047659 JULY 2010 Page 4A-47

Powerhead
Cleaning Piston Ring Grooves

Keystone (tapered) ring grooves:
1. Use a bristle brush and carbon removal solution to remove carbon from the side surfaces.
2. A tool can be made for cleaning the inner diameter of the tapered ring grooves using a broken tapered piston ring with the
side taper removed. The inside edge of the ring reaches the inner diameter of the groove. Carefully scrape carbon from inner
diameter of ring grooves. Take care not to damage the grooves by scratching the side surfaces of the grooves.
a - Ring grooves
8652
Measuring Piston Roundness

The piston has a barrel profile shape and is not a true diameter.
Using a micrometer, measure dimension "a" at location shown. Dimension "a" should be as indicated in chart following.
Piston Type CastAluminum

Using a micrometer, measure the piston diameter (dimension "a") 24 mm (0.945
in.) from the bottom of the skirt.
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.
Page 4A-48 90-8M0047659 JULY 2010

Powerhead
5. Clean the crankshaft surfaces with crocus cloth.
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.

2-Cycle Premium
14 Crankshaft journals 92-858021K01
Outboard Oil
Crankshaft and End Cap Bearings

1. Move the outer race on the lower crankshaft ball bearing back and forth. There should not be excessive play.
2. Lubricate the ball bearing with 2Cycle Premium Outboard Oil. Rotate the outer bearing race. The bearing should have smooth
action and no rust stains. If the ball bearing sounds or feels rough, remove and discard the bearing. Refer to Cylinder Block
Disassembly.

2-Cycle Premium
14 Lower crankshaft ball bearing 92-858021K01
Outboard Oil
90-8M0047659 JULY 2010 Page 4A-49

Powerhead
3. Lubricate the center main bearings with 2Cycle Premium Outboard Oil and install the center main bearings onto the crankshaft
journals.
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.
a - Upper roller bearing
10569

2-Cycle Premium
14 Center main bearings and upper roller bearing 92-858021K01
Outboard Oil
Reed Block Assembly

IMPORTANT: Do not remove the reeds from reed blocks unless replacement is necessary. Do not turn used reeds over for reuse.
Replace reeds in sets.
NOTE: The 115 Pro XS reed blocks do not have reed stops. The reeds are made of carbon fiber for improved flow capability.
1. Thoroughly clean the gasket surfaces of the reed blocks and reed block housing. Check for deep grooves, cracks, or distortion
that could cause leakage. Replace parts as necessary.
2. Inspect the reed block neoprene surface for wear, cuts, or abrasions. Replace the reed blocks as necessary.
3. Check for chipped and broken reeds.
a - 0.51 mm (0.020 in.) opening
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.).
Page 4A-50 90-8M0047659 JULY 2010

Powerhead
End Bearing Bleed System

1. Check the rubber bleed hoses. Replace any cracked, cut or deteriorating hoses.
2. Check operation of the lower end cap check valve. If the valve is working properly, air can be drawn through the check valve
one way only. If air can pass through a check valve both ways, replace the valve.
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
90-8M0047659 JULY 2010 Page 4A-51

Powerhead
6. Check for brinelling, which is the result of a combination of low speed low load cold water temperature operation, aggravated
by inadequate lubrication or improper fuel. Under these conditions, the crankshaft journal is hammered by the connecting
rod. As ignition occurs in the cylinder, the piston pushes the connecting rod with tremendous force, and this force is transferred
to the connecting rod journal. Since there is little or no load on the crankshaft, it bounces away from the connecting rod. The
crankshaft then remains immobile for a split second until the piston travel causes the connecting rod to catch up to the waiting
crankshaft journal, then hammers it. The repetition of this action causes a rough bearing surface which resembles a tiny
washboard. In some instances, the connecting rod crankpin bore becomes highly polished. During operation, the engine will
emit a whir or chirp sound when it is accelerated rapidly from idle speed to approximately 1500 RPM, then quickly returned
to idle. If the preceding conditions are found, replace both the crankshaft and connecting rods.
a - Brinelling
a
8692
7. Check for uneven wear. Uneven wear could be caused by a bent connecting rod.
a - Uneven wear
a
8694
8. If necessary, clean the connecting rod bearing surfaces, as follows:

a. Ensure that etched marks on the connecting rod (crankshaft end) are perfectly aligned with etched marks on the
connecting rod cap. Tighten the connecting rod cap attaching bolts securely.
IMPORTANT: Use only crocus cloth to clean the bearing surface at the crankshaft end of connecting rod. Other materials
may damage equipment.
b. Clean the crankshaft end of the connecting rod by using crocus cloth placed in a slotted, 9.5 mm (3/8 in.) diameter shaft,
as shown. Secure the shaft in a drill press and operate the press at high speed, keeping the connecting rod at a 90
angle to the slotted shaft.
IMPORTANT: Clean the connecting rod just enough to clean up bearing surfaces. Do not continue to clean after marks
are removed from bearing surfaces.
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.
Page 4A-52 90-8M0047659 JULY 2010

Powerhead
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.
Crankshaft Bearings Installation

1. Support the crankshaft journal in the press.
2. Lubricate the crankshaft ball bearing with 2Cycle Premium Outboard Oil.
3. Install the crankshaft ball bearing onto the crankshaft.
4. Use a suitable mandrel to press on the inner race of the crankshaft ball bearing. Press on the inner race of the crankshaft ball
bearing until it is firmly against the crankshaft shoulder.
d a- Crankshaft
b- Crankshaft ball bearing
c c- Suitable mandrel
d- Press
a b e- Crankshaft journal
10572

2-Cycle Premium
14 Crankshaft ball bearing 92-858021K01
Outboard Oil
5. Use a pair of snap ring pliers to install the retaining ring.
a - Retaining ring
10573
90-8M0047659 JULY 2010 Page 4A-53

Powerhead
6. Spread the crankshaft sealing rings open enough to slide over the crankshaft journal and onto the crankshaft sealing ring
location.
a - Crankshaft sealing ring
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.
14 a - Locating hole on the bearing race

b - Center main bearing retaining ring bridges both of the center
main bearing fractures
a
b 10577

2-Cycle Premium
14 Center main bearings 92-858021K01
Outboard Oil
11. Install the oil seal into the lower end cap.
NOTE: The oil seal lip must be orientated towards the inside of the end cap.
12. Lubricate the oil seal lip with 24C with Teflon.
13. Install the Oring onto the end cap.
Page 4A-54 90-8M0047659 JULY 2010

Powerhead
b
a - Oring
b - Oil seal lip
10522
a

95 2-4-C with Teflon Oil seal lip 92-802859A 1
2-Cycle Premium
14 O-ring 92-858021K01
Outboard Oil
15. Lubricate the upper crankshaft roller bearing with 2Cycle Premium Outboard Oil. Install the upper crankshaft roller bearing
onto the crankshaft.
16. Lubricate the upper crankshaft oil seal lip with 24C with Teflon.
17. Install the upper crankshaft oil seal onto the crankshaft.
NOTE: The upper crankshaft oil seal lip must be orientated towards the bottom of the crankshaft.
a - Oil seal
a b - Upper crankshaft roller
bearing
10596

2-Cycle Premium
14 Upper crankshaft roller bearing 92-858021K01
Outboard Oil
95 2-4-C with Teflon Oil seal lip 92-802859A 1
Piston and Connecting Rod Assembly

1. Place the needle bearings (34 per piston) on a clean piece of paper and lubricate each with 24C with Teflon.

95 2-4-C with Teflon Needle bearings 92-802859A 1
2. Place the sleeve (included with the piston pin tool) into the connecting rod and install the needle bearings around the sleeve
as shown.
3. Place the locating washers on the connecting rod.
IMPORTANT: Position the connecting rod part number facing towards the flywheel.
90-8M0047659 JULY 2010 Page 4A-55

Powerhead
4. Carefully position the piston over the end of the rod. Ensure that the locating washers remain in place.
a a - Sleeve (part of the piston

tool)
b b - Locating washers
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.
Page 4A-56 90-8M0047659 JULY 2010

Powerhead
8. Ensure that the lockrings are properly seated in the piston grooves.
8717
a - Lockring
b - Lockring installation tool
Lockring Installation Tool 91 93004A 2
Installing Piston Rings

1. Insert each piston ring into its respective cylinder bore.
2. Use the piston to push the piston ring approximately 12.7 mm (1/2 in.) into the cylinder bore. This ensures the piston ring is
perpendicular to the cylinder bore.
3. Check the end gap of each piston ring with a feeler gauge. The end gap must be within 0.250.46 mm (0.0100.018 in.).
c b
10625
a - Piston ring
b - Feeler gauge
c - Ring end gap
90-8M0047659 JULY 2010 Page 4A-57

Powerhead
4. Use the piston ring expander and install the piston rings with the 1T side of the piston ring orientated towards the top of the
piston. Spread the piston rings enough to slip over the piston.
T1
1T
10626
a - Top side of ring
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.
a a - Piston ring expander

b - Letter side on piston ring orientated towards the top of
the piston
8723

2-Cycle Premium
14 Piston, rings, and cylinder wall 92-858021K01
Outboard Oil
Page 4A-58 90-8M0047659 JULY 2010

Powerhead
7. Ensure the piston ring end gap is aligned with the locating pin on the piston.
a - Locating pin
10627
Connecting Rod Assembly

Connecting Rod Assembly Orientation
NOTE: The pistons are marked for correct orientation during reassembly. On the piston face, the letters "UP" must face towards
the flywheel end of the crankshaft. There also is a raised line located on the piston pin boss. This line must face the flywheel end
of the crankshaft.
27819
Letters "UP" on piston face
10632
Raised line located on the piston pin boss
Connecting Rod Assembly Installation

1. Apply Needle Bearing Assembly Lubricant onto the crankshaft connecting rod journals.
2. Apply Needle Bearing Assembly Lubricant to the connecting rod bearing cages.
90-8M0047659 JULY 2010 Page 4A-59

Powerhead
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

Needle Bearing Assembly
4 Crankshaft connecting rod journals, rod bearing cages 92-802868A 1
Lubricant
2-Cycle Premium
14 Threads and face of the connecting rod cap screws 92-858021K01
Outboard Oil
Connecting Rod Cap Alignment

1. Tighten the rod cap screws to 1.7 Nm (15 lbin.).
2. Use a pencil to check the alignment of the connecting rod and rod cap. If the pencil stops at the fracture, loosen the rod cap
screws and retighten to 1.7 Nm (15 lbin.). Check the alignment of the connecting rod and rod cap. If the pencil continues to
stop at the fracture, discard the rod.
a- Side view incorrect cap on backwards

b- End view incorrect cap on backwards
c- Side view correct
a c d- End view correct
b d
8726
Page 4A-60 90-8M0047659 JULY 2010

Powerhead
3. After ensuring the connecting rod cap is correctly aligned, the rod cap screws must be torqued to specification in three steps.

First 4.5 40
Rod cap screw Second 40.6 30
Crankshaft Assembly Installation into Cylinder Block

NOTE: The cylinder liners have a chamfered edge to aid in the installation of the crankshaft/piston rod assembly without the use
of piston ring compressors. Ensure the piston rings are centered on the piston locating pins before attempting to install the
crankshaft assembly into the cylinder block.
1. Lubricate the cylinder bores and piston rings with 2Cycle Premium Outboard Oil.

2-Cycle Premium
14 Cylinder bores and piston rings 92-858021K01
Outboard Oil
2. Install the crankshaft assembly into the cylinder block. Use a small screwdriver to compress the individual piston rings when
initially starting the piston assemblies into the cylinder block.
IMPORTANT: Do not force the crankshaft assembly into the cylinder block. If the crankshaft assembly is not sliding into the
cylinder block, remove the crankshaft assembly and verify the piston ring gaps are centered on the piston locating pins.
3. Ensure the locating pins in the cylinder block align with the holes in the center main bearings.
a a
b
10654
a - Center main bearing locating pins (hidden)

b - Piston ring locating pins
90-8M0047659 JULY 2010 Page 4A-61

Powerhead
4. Use an awl or scribe to push on the connecting rod bearing races. The races should rotate smoothly. If the races do not rotate
smoothly, the connecting rod cap is not properly aligned. If correct alignment cannot be achieved, remove the crankshaft
assembly and discard the connecting rod.
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

2-Cycle Premium Outboard
14 Crankshaft lower seal area 92-858021K01
Oil
Crankcase Cover Installation

1. Ensure the mating surfaces of the crankcase cover and the cylinder block are clear of debris and contaminants.
2. Apply Loctite 7649 Primer N to the mating surfaces of the crankcase cover and cylinder block.
Page 4A-62 90-8M0047659 JULY 2010

Powerhead
3. Apply a continuous thin bead of Loctite Master Gasket onto the mating surfaces of the crankcase cover.
a a - Loctite Master Gasket
a
10657

117 Loctite 7649 Primer N Mating surfaces of the crankcase cover and cylinder block 92-809824
12 Loctite Master Gasket Kit Mating surface of the crankcase cover 92-12564 2
4. Install the seal onto the cylinder block.
a 10658
a - Cylinder block seal
5. Install the crankcase cover onto the cylinder block.

6. Install the eight center main screws. Tighten the eight center main screws evenly until the crankcase cover contacts the
cylinder block.
7. Tighten the eight center main screws to the specified torque following the sequence shown.
90-8M0047659 JULY 2010 Page 4A-63

Powerhead
8. Install the crankcase cover perimeter screws. Tighten the perimeter screws to the specified torque following the sequence
shown.
a - Center main screws (8)

2 1 b - Perimeter screws (12)
19
20
18 17
a
4 3
16 15
14 13
6 5
12 11
b
10 9
8 7
10373

Center main screws (8) 37.9 28
Perimeter screws (12) 24.4 18
Page 4A-64 90-8M0047659 JULY 2010

Powerhead
9. Install the end cap screw and tighten all of the end cap screws to the specified torque.
a - Screw (3)
10519

Screw (3) 24.4 18
Bleed System Check Valve Installation

1. Install the four 90 check valve fittings onto the cylinder block. Tighten securely to ensure the check valve fittings will not leak.
27770
2. Install the three straight check valve fittings onto the crankcase cover. Tighten securely to ensure the check valve fittings will
not leak.
90-8M0047659 JULY 2010 Page 4A-65

Powerhead
3. Install the three 90 check valve fittings onto the crankcase cover. Tighten securely to ensure the check valve fittings will not
leak.
a - 90 check valve fitting (3)

b - Straight check valve fitting (3)
b
a
27769
Thermostat/Poppet Valve Installation

Install water pressure relief valve components, as shown. Tighten the screws to the specified torque.
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)

Screw (M8 x 35) 24.4 18
Page 4A-66 90-8M0047659 JULY 2010

Powerhead
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
3. Install the flywheel, washer, and flywheel nut.

4. Secure the flywheel with the flywheel holding tool. Tighten the flywheel nut to the specified torque.
b
a - Flywheel holding tool
b - Torque wrench
27826

Flywheel nut 163 120
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.

95 2-4-C with Teflon Driveshaft splines 92-802859A 1
4. Install the powerhead onto the driveshaft housing. It may be necessary to turn the flywheel to align the crankshaft splines with
the driveshaft splines.
5. Install the two support plates onto the rear powerhead mounting studs. Ensure the protrusions on the support plates are facing
down. Retain the support plates with four nuts. Do not tighten the nuts at this time.
90-8M0047659 JULY 2010 Page 4A-67

Powerhead
6. Install four washers onto the remaining four mounting studs. Retain the washers with four nuts. Do not tighten the nuts at this
time.
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

First 27 20
Nut (8)
Installing Engine Component Assemblies

Flush Hose and Shift Bracket Installation
1. Install the crankshaft position sensor to the cylinder block and secure with two screws. Tighten the screws to the specified
torque.
Page 4A-68 90-8M0047659 JULY 2010

Powerhead

Crankshaft position sensor screw (M5 x 16) (2) 5 44.2
2. Install an Oring onto the temperature sensor assembly.
13384
3. Apply Loctite 567 PST Pipe Sealant to the threads of the temperature sensor assembly.

9 Temperature sensor assembly threads 92-809822
Sealant
4. Install the temperature sensor assembly into the cylinder block. Tighten the temperature sensor assembly to the specified
torque.

Temperature sensor assembly 15 133
5. Apply Loctite 567 PST Pipe Sealant to the threads of the Legris fitting. Install the Legris fitting onto the cylinder block. Tighten
the Legris fitting securely.
6. Apply Loctite 567 PST Pipe Sealant to the threads of the flushing hose fitting. Install the flushing hose fitting into the cylinder
block. Tighten the flushing hose fitting securely.

9 Legris fitting threads and flushing hose fitting threads 92-809822
Sealant
7. Install the flushing hose to the flushing hose fitting and secure with a cable tie.
a a- Crankshaft position sensor

b- Water temperature sensor
c- Legris fitting
b d- Cable tie securing the flushing hose
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.

Shift bracket screws (M8 x 25) (2) 24.4 18
90-8M0047659 JULY 2010 Page 4A-69

Powerhead
9. 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

95 2-4-C with Teflon Shift bracket 92-802859A 1
10. Install the bushing onto the shift link so the bushing flange is on top of the shift link.
11. Install the shift link onto the shift slide stud. Secure the shift link to the shift slide stud with a washer and locknut. Tighten the
locknut to the specified torque.
c c a- Shift link
b
b- Shift bracket
d- Locknut and washer securing
shift link to shift slide
a
d
27705

Locknut 5.7 50.5
Reed Plate Assembly

Reed Block Installation
1. Ensure the reed plate is clear of debris.
2. Install new reed block gaskets onto the reed plate.
3. Install the reed blocks onto the reed plate.
4. Apply Loctite 271 Threadlocker to the threads of the reed block screws.
Page 4A-70 90-8M0047659 JULY 2010

Powerhead
5. Secure the reed blocks to the reed plate with two screws for each reed block. Tighten the screws to the specified torque.
27536

7 Loctite 271 Threadlocker Reed block screw threads 92-809819

Reed block screw (6) 10.2 90
Reed Plate Installation

1. Ensure the crankcase cover does not have any gasket material on the mating surface.
2. Install the reed plate to the crankcase cover with a gasket.
3. Retain the reed plate to the crankcase cover with a retaining bracket and screw in the top hole of the reed plate.
4. Secure the reed plate to the crankcase cover with the remaining 14 screws. Tighten the screws to the specified torque in the
sequence shown.
a
10 a - Retaining bracket
8 9
7 6
5
3 4
2 1
11
12
13
15 14
27842

Screw (M8 x 35) (15) 24.4 18
90-8M0047659 JULY 2010 Page 4A-71

Powerhead
Oil Line Routing
10501
Page 4A-72 90-8M0047659 JULY 2010

Powerhead
Recirculation and Oil Pump Line Installation

Recirculation Line Installation
1. Install the short recirculation line onto the lower end cap check valve fitting.
a a - Lower end cap

b - Short recirculation line
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.
c a- Short recirculation line on the cylinder block

b- Tfitting
c- Check valve fitting on top of the reed block plate
d- Short recirculation line connected to the lower end cap check valve fitting
d
27840
Oil Pump Line Installation

IMPORTANT: The oil pump has seven oil delivery fittings. Six of the oil delivery fittings are for the powerhead. The seventh oil
delivery fitting is for the air compressor. The air compressor requires a different volume of oil than the powerhead. Failure to ensure
the oil pump lines are correctly installed will cause a powerhead failure.
1. If the oil pump line was removed or replaced, refer to the Oil Line Routing to verify the correct routing of the oil pump lines.
2. Install the oil pump lines to the crankcase main bearing straight check valve fittings and secure with cable ties.
3. Install the oil pump lines to the 90 crankcase check valve fittings and secure with cable ties.
90-8M0047659 JULY 2010 Page 4A-73

Powerhead
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
Air Compressor Assembly Installation

1. Install the oil return line to the cylinder block check valve fitting and secure with a cable tie.
27686
2. Install the air compressor to the cylinder block and secure with three screws. Tighten the screws to the specified torque.
27685

Air compressor screws (M8 x 90) (3) 24.4 18
Page 4A-74 90-8M0047659 JULY 2010

Powerhead
3. Install the oil return lines to the check valve fittings on the cylinder block and secure with cable ties.
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.
c a - Cable tie securing the water hose

b - Retainer securing the water hose
b c - Cable tie securing the oil line
27679
Starter Motor Installation

1. Ensure the starter stop is installed.
a - Starter stop
27107
90-8M0047659 JULY 2010 Page 4A-75

Powerhead
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 screw through the starter ground eyelet.

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 starter ground and starter mounting screw.
a
a - Starter ground
b - Screw (4)
27665

Starter mounting bracket screw (M8 x 35) (4) 24.4 18

25 Liquid Neoprene Starter ground and mounting screw 92- 25711 3
Electrical Harness Assembly Installation

1. Ensure two of the M8 x 35 electrical bracket mounting screws have a small washer on them.
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.
Page 4A-76 90-8M0047659 JULY 2010

Powerhead
6. Install the battery positive cable to the power post and secure with a nut and lockwasher. Tighten the nut to the specified
torque. Protect the power post with the red insulator boot.
a a - Red insulator boot

b b - Screw and large washer
c - Screw and small washer securing the ground wire
and electrical bracket
c
27677

Screw (M8 x 35) (2) 24.4 18
Nut 13.5 120

25 Liquid Neoprene Screw securing ground wire eyelet 92- 25711 3
7. Insert a screw with the small washer through the ground strap. Secure the electrical plate to the cylinder block with the screw.
Tighten the screw to the specified torque.
8. Apply Liquid Neoprene to the screw securing the ground strap.
a a - Screw
b - Ground strap
27676

Screw (M8 x 35) 24.4 18

25 Liquid Neoprene Ground screws and straps 92- 25711 3
9. Secure the air hose to the electrical bracket with the retainer.
10. Connect the engine harness connector to the air compressor temperature sensor assembly connector.
90-8M0047659 JULY 2010 Page 4A-77

Powerhead
11. Connect the engine harness connector to the crankshaft position sensor.
b a - Retainer securing the air hose

b - Air compressor temperature sensor
connector
a c - Crankshaft position sensor connector
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.
b a- Red insulating boot covering the starter power cable

b- Starter exciter wire
c c- Electrical plate ground wire
d d- Battery negative cable
27674

Nut securing the starter power cable 10 88.5
Nut securing the starter exciter wire 2.5 22
Screw securing the electrical plate ground wires (M6 x 14) 10 88.5
Screw securing the negative battery cable (M6 x 14) 10 88.5

25 Liquid Neoprene Ground screws, straps, and starter exciter wire terminal 92- 25711 3
18. Connect the trim motor bullet connectors to the engine harness bullet connectors.
Page 4A-78 90-8M0047659 JULY 2010

Powerhead
19. Connect the shift switch bullet connectors to the engine harness bullet connectors.
a - Trim position sender wire

b - Trim motor bullet connectors
c - Shift switch bullet connectors
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.
b a - Screws securing the 14 pin harness bracket (2)

b - Clip
27671

Screw (M6 x 25) (2) 11 98
24. Secure the oil pump to the electrical harness bracket with three M8 x 20 screws. Tighten the screws to the specified torque.
90-8M0047659 JULY 2010 Page 4A-79

Powerhead
25. Connect the engine harness connector to the oil pump.

b b - Screws securing the oil pump (3)
27670

Screw (M8 x 20) (3) 24.4 18
Alternator Assembly Installation

1. Install washers onto the three alternator mounting bracket screws. Insert the screws onto the alternator mounting bracket.
2. Install washers onto the three screws protruding through the alternator mounting bracket.
3. Slide the alternator assembly under the flywheel and onto the cylinder block. Align the washers and screws with the threaded
holes on the cylinder block. Tighten the three alternator mounting bracket screws to the specified torque.
b a - Screw (3) and washer (6)

a b - Alternator ground
27669

Screw (M10 x 45) (3) 47.5 35
4. Connect the exciter wire harness connector to the alternator.
5. Install the battery charging fusible link cable to the alternator terminal and secure with a washer and locknut. Tighten the
locknut to the specified torque. Protect the alternator battery charging terminal with the red insulating boot.
a - Large washer (3)

a b - Exciter wire harness connector
a c - Red insulating boot
b c
27854
Page 4A-80 90-8M0047659 JULY 2010

Powerhead

Locknut 5.6 50
6. Secure the alternator ground to the cylinder block with a screw. Tighten the screw to the specified torque. Apply Liquid
Neoprene to the alternator ground screw.
27666

Alternator ground screw (M6 x 12) 10.2 90

25 Liquid Neoprene Alternator ground screw 92- 25711 3
Air Plenum and Throttle Body Assembly Installation

1. Ensure the mating surfaces of the air plenum and the reed plate are clear of debris.
2. Install a new gasket onto the air plenum.
90-8M0047659 JULY 2010 Page 4A-81

Powerhead
3. Secure the air plenum to the reed plate with nine screws. Tighten the nine screws to the specified torque in the sequence
shown.
8 7
3
1
4
2
5 6
27878

Screw (M8 x 45) (9) 24.4 18
4. Connect the engine harness connector to the MAP sensor connector.

5. Connect the engine harness connector to the manifold air temperature sensor connector.
Page 4A-82 90-8M0047659 JULY 2010

Powerhead
6. Connect the engine harness connector to the throttle position sensor connector.
a - MAP sensor connector

b - Throttle position sensor connector
c - Manifold air temperature sensor connector
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.
a - Screw securing the throttle lever

b - Screw securing the throttle cable bracket
10065

Screw (M10 x 45) 27 20
Screw (M6 x 16) 10.2 90
90-8M0047659 JULY 2010 Page 4A-83

Powerhead

7 Loctite 271 Threadlocker Screw threads securing the throttle lever 92-809819
Vapor Separator Tank Assembly Installation

1. Install the two large spacers, grommets, and washers to the cylinder block and secure with two M8 x 60 screws. Tighten the
screws to the specified torque.
a a- Large spacer
b- Grommet
c- Washer
b d- Screw
d 27894

Screw (M8 x 60) (2) 24.4 18
2. Install the VST onto the grommets.

3. Position the VST onto the cylinder block with a bushing and grommet. Secure the VST to the cylinder block with a washer
and M8 x 35 screw. Tighten the screw to the specified torque.
4. Install the fuel pump pulse hoses to the cylinder block fittings. Secure the fuel pump pulse hoses to the cylinder block fittings
with cable ties.
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

Screw (M8 x 35) 24.4 18
Page 4A-84 90-8M0047659 JULY 2010

Powerhead
6. Secure the VST vent hose to the alternator bracket with a cable tie. Do not overtighten the cable tie.
27910
7. Connect the engine harness connector to the VST fuel pump connector.
27912
Fuel Rail Installation

1. Inspect the direct injector Orings and Teflon ring for cuts or abrasions.
2. If the Teflon seal requires replacement, use the seal/Teflon ring installation tool to slide the new seal onto the injector. Use
the Teflon ring sizing tool to compress the Teflon seal.
a
b c d a- Orings
b- Seal/Teflon ring installation tool
c- Teflon seal
d- Seal/Teflon ring sizing tool
27190

90-8M0047659 JULY 2010 Page 4A-85

Powerhead
3. Lubricate the direct injector Orings with 2Cycle Premium Outboard Oil.
27916

2-Cycle Premium
14 Direct injector O-rings 92-858021K01
Outboard Oil
4. Install the fuel rail and secure with two M10 nuts. Tighten the nuts to the specified torque.
5. Connect the three engine harness connectors to the direct injectors.
6. Connect the three engine harness connectors to the fuel injectors.
a - Fuel injector connector

b - Direct injector connector
c - Nut (M10)
b
c
27917

Nut (M10) 44.7 33
Page 4A-86 90-8M0047659 JULY 2010

Powerhead
7. Ensure the seal and Oring are installed on the fuel return hose fitting. Lubricate the seal and Oring with 2Cycle Premium
Outboard Oil.
b a - Seal
b - Oring
a
27919

2-Cycle Premium
14 Fuel return hose seal and O-ring 92-858021K01
Outboard Oil
8. Apply Loctite 271 Threadlocker to the M6 x 12 screw threads. Secure the fuel return hose to the VST with a retainer plate
and screw. Tighten the screw to the specified torque.

b - Retainer plate
27920

Screw (M6 x 12) 10.2 90

7 Loctite 271 Threadlocker Retainer plate screw threads 92-809819
9. Ensure there are two Orings on the fuel delivery hose.
10. Lubricate the Orings with 2Cycle Premium Outboard Oil.
a - Orings (2)
27930
90-8M0047659 JULY 2010 Page 4A-87

Powerhead

2-Cycle Premium
14 Fuel delivery hose O-rings 92-858021K01
Outboard Oil
11. Apply Loctite 271 Threadlocker to the two M5 x 10 screw threads. Secure the fuel delivery hose to the fuel rail with a retainer
plate and two screws. Tighten the screws to the specified torque.
a - Screw (M5 x 10) (2)

b - Retainer plate
a
b
27931


Screw (M5 x 10) (2) 8 71
12. Ensure there is an Oring on the air delivery hose fitting.
a - Oring
27932

2-Cycle Premium
14 Air delivery hose fitting O-ring 92-858021K01
Outboard Oil
14. Apply Loctite 271 Threadlocker to the two M5 x 10 screw threads. Secure the fuel delivery hose to the fuel rail with a retainer
plate and two screws. Tighten the screws to the specified torque.


Screw (M5 x 10) (2) 8 71
Page 4A-88 90-8M0047659 JULY 2010

Cooling
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
90-8M0047659 JULY 2010 Page 4B-1

Cooling
Thermostat
Water pressure
At 625 RPM (idle) 20.641.3 kPa (36 psi)
At 5750 RPM (WOT) 75.896.5 kPa (1114 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)

9 Water strainer fitting threads 92-809822
Sealant
Special Tools
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
1.5 Liter OptiMax Water Flow

Description
Water enters the cooling system through the lower unit water inlets. The water pump assembly is driven by the driveshaft and
forces water through the water tube up to the exhaust adapter plate and into the cylinder block exhaust side. There are passages
in the cylinder block exhaust side to supply water to three locations.
Water exits through the strainer screen which leads to the air compressor, fuel rail, and telltale.
Some water exits at the top of this chamber through a passageway leading to an area around the cylinders.
The main flow of water exits at the bottom of the chamber into passageways around the cylinders.
Water then flows past the cylinders to the top of the cylinder block. Water deflectors inside the cylinder block direct water up the
port side of the cylinders and down the starboard side. The water then enters the cylinder dome area, starting at the bottom of the
cylinder block flowing to the top. Water exiting the cylinder block is controlled by the poppet valve and the thermostat.
The thermostat controls water flow at idle and at off idle engine RPM. When the correct temperature is reached, the thermostat
opens and allows the water to exit the cylinder block.
The poppet valve controls water pressure at higher engine RPM. When the water pressure reaches the amount of the poppet
valve spring pressure, the poppet valve is forced open, allowing a large volume of water to dump out of the cylinder block.
Page 4B-2 90-8M0047659 JULY 2010

Cooling
Water exits the block through a passageway at the port rear corner of the cylinder block. The water then passes through the
adapter plate into the driveshaft housing, forming a wall of water between the exhaust tube and the inside of the driveshaft housing,
exiting onto the driveshaft housing near the anode on the lower unit.
Thermostat
Inspect the thermostat. Replace if damaged, seized, or corroded.
Thermostat Measurement Test

1. Tie a piece of thread or other nonconductive material onto the thermostat.
2. Suspend the thermostat in cold water.
3. Suspend a thermometer in the water.
IMPORTANT: Do not allow the thermometer to contact the heating surface of the container. An inaccurate temperature reading
may result.
4. Slowly heat the water while observing the thermostat and thermometer.
5. Measure the thermostat opening when the specified water temperature is achieved.
3120
a - Minimum thermostat valve lift
Cylinder Block Coolant Temperature Sensor

The cylinder block coolant temperature sensor is located above and to the left of cylinder number one spark plug. It is a thermistor
immersed in the engine coolant path and supplies the PCM with engine temperature information. The PCM adjusts the timing and
the amount of fuel delivered according to the water temperature in the cylinder block. Low coolant temperature produces high
resistance, while high temperature causes low resistance.
The CDS will help determine the proper functioning of the cylinder block coolant temperature sensor by providing a numerical
readout of the block coolant temperature before and after the engine is started. With the engine not running, block temperature
should be approximately the same as the ambient air temperature. After the engine is started, the temperature sensor should
indicate a rise in block coolant temperature to approximately 60 70 C (140 158 F). Outside air temperature and the temperature
of the water that the engine is operating in will directly affect the engine block temperature.
Refer to Section 2A - Cylinder Block Coolant Temperature Sensor for the removal, installation, and testing of the air compressor
head temperature sensor.

26966
90-8M0047659 JULY 2010 Page 4B-3

Cooling
Air Compressor Head Temperature Sensor

The air compressor head temperature sensor is a thermistor immersed in the coolant path of the air compressor and supplies the
PCM with air compressor temperature information. The PCM monitors this temperature and warns the operator of a potentially
damaging high temperature. The PCM activates the warning horn and will limit engine RPM. A low temperature produces high
resistance, high temperature causes low resistance.
The CDS will help determine the proper functioning of the air compressor head temperature sensor by providing a numerical
readout of the air compressor head temperature before and after the engine is started. With the engine not running, the air
compressor head temperature should be approximately the same as the ambient air temperature. After the engine is started, the
temperature sensor should indicate a rise in the air compressor head temperature. Outside air temperature and the temperature
of the water that the engine is operating in, will directly affect the air compressor head temperature.
Refer to Section 2A - Air Compressor Head Temperature Sensor for the removal, installation, and testing of the air compressor
head temperature sensor.
26974
Troubleshooting
Water Pressure Check
Check the water pressure using one of these three methods:
Use the computer diagnostic system (CDS).

On engines equipped with SmartCraft gauges, water pressure is an available readout.
Temporarily connect a dash style analog water pressure gauge into the water pressure sensor gray tube. A Tfitting P/N
875207 and short piece of bulk gray tubing P/N 859785 71 is required to make this connection.
IMPORTANT: Shut off the engine and refer to the troubleshooting chart if water pressure is not within specification. Do not
exceed 3000 RPM in neutral.
Water Pressure
Idle 20.641.3 kPa (36 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.
Page 4B-4 90-8M0047659 JULY 2010

Cooling
4. Connect the water hose to the water strainer and secure with a cable tie.
a - Water strainer
10728

9 Water strainer fitting threads 92-809822
Sealant
Water Pressure Sensor

The water pressure sensor is located near cylinder #1. The water pressure sensor is monitored by the PCM at 1200 RPM and
above. If the water pressure does not exceed the minimum specification at 1200 RPM and above, the PCM will activate the warning
horn and reduce the RPM accordingly.
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
90-8M0047659 JULY 2010 Page 4B-5

Cooling
Water Pump Cleaning and Inspection

1. Inspect the water tube coupling for wear or damage.
a - Water tube coupling

b - Orings
a b
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.
a a - Water pump face plate

b - Water pump cover
b 8749
6. Inspect the rubber seal for damage.
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.
Page 4B-6 90-8M0047659 JULY 2010

Cooling
Cooling System Diagnosis

Condition Recommended Range Possible Cause
Poppet valve spring defective
(weak, broken, missing)
Defective poppet valve seal
Pressure below specification at idle 20.641.3 kPa (36 psi) Severe internal leak
Thermostat stuck open
Low water pump output
Water inlet restriction
Compressor overheats weak or no Strainer screen for air compressor

telltale water supply is restricted
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
Wrong poppet valve spring

Pressure does not drop between 1200 Water inlet restriction
48.362.1 kPa (79 psi) between 12002100
2100 RPM indicating poppet valve has
RPM Poppet valve vent hole plugged or
opened
restricted
Severe internal leak
Poppet valve spring defective

(weak, broken, strong, missing)
Broken diaphragm in poppet valve
Poppet valve flutter/water pressure drop 48.362.1 kPa (79 psi) between 12002100
does not start prior to 1500 RPM RPM Severe internal leak
Wrong poppet valve spring

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
Restriction on discharge side of

cooling system
75.896.5 kPa (1114 psi) Note: A modified
propeller, or low pitch propeller, is required to Engine mounted high or trimmed too
check water pressure at WOT when the boat far out, resulting in formation of
Pressure exceeds specification at WOT is stationary. The boat must be in the water steam pockets in cooling system
and secured to a dock or trailer and run in If boat is being run on open water,
forward gear. Do not perform this check using ram effect of water on coolant inlets
a flush device. at high speeds may increase water
pressure above specifications
90-8M0047659 JULY 2010 Page 4B-7

Cooling
Condition Recommended Range Possible Cause

Water inlet restriction
Engine mounted too high on
transom
Engine trimmed out too far
Pressure is below specification at WOT 75.896.5 kPa (1114 psi) Configuration of boat bottom
interfering with adequate flow of
water to coolant inlets
Water outlet passages restricted

Pressure higher than normal at WOT, Steam pocket has formed at top of
but engine still indicates overheat Maximum pressure 158.6 kPa (23 psi) powerhead due to lack of cooling
condition water
Page 4B-8 90-8M0047659 JULY 2010

Clamp/Swivel Brackets and Driveshaft Housing
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
90-8M0047659 JULY 2010 Page 5A-1

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.)

High Performance Gear
87 Nut threads 92-858064K01
Lubricant
Swivel pin bushings, steering link bushing
Grease fittings, O-rings
Shift link bushings, shift shaft bushing
95 2-4-C with Teflon Exhaust tube seal, water tube seal 92-802859A 1
Shift shaft bushing
Swivel pin assembly
Tilt tube
Page 5A-2 90-8M0047659 JULY 2010

Notes:
90-8M0047659 JULY 2010 Page 5A-3

Swivel Bracket and Steering Arm

11
95
10
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
Page 5A-4 90-8M0047659 JULY 2010

Swivel Bracket and Steering Arm

Torque
1 1 Swivel bracket
2 1 Oil seal
3 2 Bushing
4 1 Oring
5 1 Spacer
6 2 Grease fitting 4.5 40
7 2 Bushing
8 2 Screw (0.2528 x 0.50) 11.5 100
9 1 Swivel pin
10 1 Steering link assembly
11 1 Screw (0.37524 x 1.25) 27 20
12 2 Nut (0.37524)
13 2 Washer
14 2 Bumper
15 1 Bottom yoke
16 1 Retaining ring
17 1 Thrust washer
18 1 Overlaminate decal
19 1 Serial number decal
20 1 Power trim sender kit
21 1 Cable
22 2 Screw (1024 x 0.75)
23 2 Lockwasher
24 2 Washer

95 2-4-C with Teflon Swivel pin bushings, steering link bushing 92-802859A 1
90-8M0047659 JULY 2010 Page 5A-5

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
Page 5A-6 90-8M0047659 JULY 2010

Transom Bracket
Torque
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)

87 Nut threads 92-858064K01
Lubricant
95 2-4-C with Teflon Grease fittings, O-rings 92-802859A 1
90-8M0047659 JULY 2010 Page 5A-7

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
Page 5A-8 90-8M0047659 JULY 2010

Exhaust Plate
Torque
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

95 2-4-C with Teflon Shift link bushings, shift shaft bushing 92-802859A 1
90-8M0047659 JULY 2010 Page 5A-9

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
Page 5A-10 90-8M0047659 JULY 2010

Driveshaft Housing
Torque
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
90-8M0047659 JULY 2010 Page 5A-11

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
Page 5A-12 90-8M0047659 JULY 2010

Bottom Cowl
Torque
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
90-8M0047659 JULY 2010 Page 5A-13

Bottom Cowl Removal

1. Disconnect the cowl tilt switch connector from the engine harness connector.
10393
2. Remove the four screws securing the cowl halves together.

3. Loosen the screw securing the front cowl halves together.
4. Remove the two screws securing the upper clamp.
a- Screw (M6 x 40) (4)

b
b- Screw (M6 x 16) (1)
c- Nut (M8) (2)
a d- Screw (M6 x 16) (2)
e- Idle relief boot
e d
10736
Bottom Cowl Installation

1. Verify the idle relief boot is between the cowl halves. Check the engine wiring, water hoses, and trim wires to ensure they are
not pinched during the bottom cowl installation.
2. Secure the cowl halves together with screws and nuts.
3. Install the upper clamp and secure with two screws.
4. Secure the front of the cowl halves together with a screw.
Page 5A-14 90-8M0047659 JULY 2010

5. Tighten all screws to the specified torque.
a- Screw (M6 x 40) (4)

b
b- Screw (M6 x 16) (1)
c- Nuts (M8) (2)
a d- Screw (M6 x 16) (2)
e- Idle relief boot
e d
10736

Screw (M6 x 40) 7.3 65
Screw (M6 x 16) 7.3 65
Nut (M8) 20.3 15
6. Connect the engine harness connector to the cowl tilt switch connector.
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.
90-8M0047659 JULY 2010 Page 5A-15

5. Remove the four screws securing the upper mount clamp to the exhaust plate and remove the clamp.
a a - Shift shaft assembly

b - Wiring harness
c - Screws
b
10742
6. Remove the screws securing the lower mount covers to the driveshaft housing and remove the covers.
a - Screws
b - Cover
10744
Page 5A-16 90-8M0047659 JULY 2010

7. Remove the screws securing the lower mount retainers to the driveshaft housing and remove the lower mount retainers.
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.
a - Lower mount nut
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.
90-8M0047659 JULY 2010 Page 5A-17

12. Remove the three screws securing the exhaust plate to the 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.
Page 5A-18 90-8M0047659 JULY 2010

15. Remove the six screws securing the exhaust tube to the exhaust plate and remove the exhaust tube. Remove all the gasket
material from the exhaust plate. Inspect the water tube seal for damage. Replace the water tube seal if damaged.
a- Water tube
b- Screw (M8 x 45)
c- Exhaust tube
d- Screw (M8 x 35)
e- Water tube seal
d e
b 10753
Driveshaft Housing Assembly and Installation

1. Inspect the exhaust tube seal and water tube seal for cuts, tears, or heat damage. Replace the seals if damaged.
2. Apply 24C with Teflon to the outside surface of the exhaust tube seal.
90-8M0047659 JULY 2010 Page 5A-19

3. Apply 24C with Teflon to the inside surface of the water tube seal in the driveshaft housing.
a - Exhaust tube seal

b - Water tube seal
b
10759

95 2-4-C with Teflon Exhaust tube seal, water tube seal 92-802859A 1
4. Install a new gasket onto the exhaust plate. Secure the exhaust tube to the exhaust plate with six M8 x 35 screws. Tighten
the screws to the specified torque.
Page 5A-20 90-8M0047659 JULY 2010

5. Secure the water tube to the exhaust plate with the clamp and two M8 x 45 screws. Tighten the screws to the specified torque.
a- Gasket
b- Exhaust tube
c- Screw (M8 x 35) (6)
d- Water tube
e- Screw (M8 x 45) (2)
c c
e
10760

Screw (M8 x 35) 27 20
Screw (M8 x 45) 20.3 15
6. Install the exhaust plate assembly into the driveshaft housing.
90-8M0047659 JULY 2010 Page 5A-21

7. Secure the exhaust plate to the driveshaft housing with a M8 x 70 screw and two M8 x 35 screws. Tighten the screws to the
specified torque.
a - Screw (M8 x 35)

b - Screw (M8 x 70)
c - Adapter plate
10790

Screw (M8 x 35) 33.9 25
Screw (M8 x 70) 33.9 25
8. Install a rubber washer and a flat washer onto the lower mount.
9. Insert the ground wire onto the M12 x 154 bolt.
10. Insert the M12 x 154 bolt with the ground wire through a lower mount. The hex bolt and ground wire must be on the same
side of the lower mount as the washers.
11. Install the lower mount assembly onto the driveshaft housing.
12. On the port side lower mount only, insert the ground wire onto a M8 x 25 screw.
13. Secure the lower mount to the driveshaft housing with the mount clamp and two M8 x 25 screws. Tighten the screws to the
specified torque.
14. Install the opposite side lower mount the same way.
a- Bolt (M12 x 154) (2)

b- Flat washer (2)
c- Rubber washer (2)
f
d- Retainer plate (2)
e- Screw (M8 x 25) (4)
a f- Ground cable port side only
10798
c b
d

Screw (M8 x 25) 27 20
15. Install the upper mounts onto the exhaust plate with the arrow pointing towards the swivel pin.
Page 5A-22 90-8M0047659 JULY 2010

NOTE: The upper mounts may have the word "FORWARD" embossed into the rubber and must be installed pointing towards
the swivel pin.
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

Screw (M8 x 35) 27 20
90-8M0047659 JULY 2010 Page 5A-23

17. Install the leather bumpers onto the swivel bracket.
a - Leather bumpers (2)
10822
18. Slide the driveshaft housing assembly onto the swivel bracket.
Page 5A-24 90-8M0047659 JULY 2010

19. Install the upper mount retainer and secure the driveshaft housing to the swivel bracket with two M12 nuts. Tighten the nuts
to the specified torque.
a - Retainer
b - Nuts
10832

Nut (M12) 74.5 55
20. Install a washer onto the lower mount bolts.
21. Install the ground wire onto the port side lower mount bolt.
22. Secure the lower mounts to the bottom yoke with two M12 nuts. Tighten the nuts to the specified torque.
a - Nuts
b - Ground wire (port side)
10836
90-8M0047659 JULY 2010 Page 5A-25


Nut (M12) 67.8 50
23. Install the mount covers and secure the mount covers with two 1224 x 0.620 screws. Tighten the screws to the specified
torque.
a - Cover
b - Screws
a
10841

Screw (1224 x 0.620) 2.3 20
24. Install the shift shaft bushing into the clamp securing the upper mounts.
25. Lubricate the bushing with 24C with Teflon and install the shift shaft.

95 2-4-C with Teflon Shift shaft bushing 92-802859A 1
Page 5A-26 90-8M0047659 JULY 2010

26. Install the trim harness into the clamp.
c
a - Shift shaft assembly
b - Trim harness
c - Shift link nut (M6)
10846
27. Install the lower unit. Refer to Section 6A - Gear Housing.

28. Install the powerhead. Refer to Section 4A - Powerhead.
Transom/Swivel Bracket
Disassembly
1. Trim to full up position. Engage tilt lock lever.
a - Tilt lock
21591
90-8M0047659 JULY 2010 Page 5A-27

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
3. Remove the trilobe pin from the upper tilt shaft.

4. Remove the upper tilt pin from the swivel bracket and trim cylinder eye.
a - Trim cylinder rod

b - Trilobe pin
c - Upper tilt pin
c
21594
5. Remove the 11/4 in. hex nut on the tilt tube.

6. Support the swivel bracket while removing the tilt tube from the transom bracket/swivel bracket assembly.
Page 5A-28 90-8M0047659 JULY 2010

7. Remove the swivel bracket and wave washers.
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
Swivel Bracket/Pin Disassembly

1. Remove the retaining ring on the bottom of the swivel pin assembly.
a- Swivel bracket
b- Retaining ring
a c- Bottom yoke
d- Swivel pin
d 21580
2. Remove the swivel pin assembly from the swivel bracket.

3. Remove the thrust washer and seal from the top of the swivel bracket.
4. Remove the spacer and Oring from the bottom of the swivel bracket.
5. Remove old grease from the swivel bracket bore and clean the bore.
90-8M0047659 JULY 2010 Page 5A-29

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
Swivel Bracket/Pin Assembly

1. Install a new seal, lip side up (out), into the top of the swivel bracket.
a - Swivel bracket
a b - Seal
c - Bushing
c
b
15563
2. Install the thrust washer onto the swivel pin.
a - Swivel pin assembly

b - Thrust washer
b
15612
Page 5A-30 90-8M0047659 JULY 2010

3. Install the Oring into the bottom of the swivel bracket.

4. Install the swivel pin assembly into the swivel bracket.
5. Install the spacer, flat side down (out), over the swivel pin and into the swivel bracket.
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.

95 2-4-C with Teflon Swivel pin assembly 92-802859A 1
Transom/Swivel Bracket Assembly

1. Assemble the swivel bracket/swivel pin assembly and wave washers between the transom brackets.
2. Insert the tilt tube through the transom brackets and the swivel bracket.
90-8M0047659 JULY 2010 Page 5A-31

3. Tighten the tilt tube nuts to the specified torque.
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

Port tilt tube locknut (e) 62 45.7
68 50
Starboard tilt tube locknut (g)
then back off 90
4. Align the power trim cylinder rod eye and the swivel bracket cross holes.
NOTE: The chamfered hole in the trim rod eye faces aft.
5. Insert the upper pivot shaft through the swivel bracket and power trim cylinder rod eye.
NOTE: The slotted end of the pivot pin faces the trim position sensor.
a a- Upper swivel shaft (slot is in line with cross hole)

b- Chamfered end of hole (faces away from transom)
c- Trilobe pin
d- Trim ram end
c b
9201
6. Insert a punch into the trim cylinder rod eye hole to align it with the cross hole in the upper swivel shaft.
Page 5A-32 90-8M0047659 JULY 2010

7. Install a new trilobe pin in the upper pivot shaft and trim cylinder rod eye. Tap the new trilobe pin in until flush.
e a- Trim cylinder rod

b- Trilobe pin
c
c- Upper pivot shaft
c d- Slotted end of pivot shaft
d
e- Swivel bracket assembly
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

Trim position sensor mounting screws 1.7 15
9. Lubricate the swivel tube assembly through the grease fitting in the swivel bracket.

95 2-4-C with Teflon Tilt tube 92-802859A 1
90-8M0047659 JULY 2010 Page 5A-33

Notes:
Page 5A-34 90-8M0047659 JULY 2010

Power Trim
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
90-8M0047659 JULY 2010 Page 5B-1

Power Trim
Power Trim Specifications

Power Trim Specifications S/N 1B417702 and Above
Trim up circuit pressure, minimum 19,300 kPa (2800 psi)
Power Trim Specifications S/N 0T8010001B417701

Trim up circuit pressure, minimum 18,202 kPa (2,640 psi)

7 Loctite 271 Threadlocker Shock rod threads 92-809819
9 Brass fitting and test adapter threads 92-809822
Sealant
Pivot pin surface and lower pivot pin bore
95 2-4-C with Teflon 92-802859A 1
Upper pivot pin and bore, trim ram bore
Power trim O-rings
Power Trim and Steering Power trim O-rings
114 92-858074K01
Fluid Power trim system
Power trim reservoir
Special Tools

V Hz
H z TEMP
mA
mV IG
OFF IP
TEMP
A mA COM V Hz
4516
Adapter Fitting 91822778A 1
91 822778 1
Measures the internal pressure in the up mode for a single cylinder trim system.
12203
Power Trim Test Gauge Kit 9152915A6
Tests circuit pressures for various trim pumps.
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.
Page 5B-2 90-8M0047659 JULY 2010

Power Trim
Expanding Rod Snap On CG4111
Aids in the removal of the spool from the power trim pump.
8753
Collet Snap On CG4114
Aids in the removal of the spool from the power trim pump.
8754
Spanner Wrench 91 74951
Removes and installs trim cylinder end caps.
8775
Trim Cylinder End Cap Tool 91821709T
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
Torch Lamp 91 63209
Heats surfaces to aid in the removal and installation of interference fit engine
components.
8776
Lockring Pliers SnapOn SRP4
Aids in the removal of lockrings.
4799
90-8M0047659 JULY 2010 Page 5B-3

Power Trim
Power Trim Components

a
16 19
18 21
20
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
Page 5B-4 90-8M0047659 JULY 2010

Power Trim
Power Trim Components

Torque
1 1 Shock rod
2 1 Oring kit
3 1 Memory piston assembly
4 1 Cylinder assembly
5 1 Trim limit valve kit
6 1 Pump assembly
7 1 Motor kit
8 1 Reservoir plug 2.8 25
9 1 Manual release assembly 2.8 25
10 1 Manifold kit
11 1 Screw kit (motor)
12 1 Cable
13 1 Driveshaft
14 1 Filter kit
15 1 Pressure operated check assembly kit
16 2 Groove pin
17 1 Anchor pin
18 1 Shaft
19 2 Clamp
20 1 Screw
21 1 Cwasher
a 1 Cylinder end cap 61 45
b 4 Motor/reservoir screw 9.6 85
c 3 Oil pump screw 8 70
d 2 Plug 13.5 120
e 2 Cylinder screw 11.3 100
f 1 Shock piston 140 103

114 Power trim O-rings 92-858074K01
Fluid
90-8M0047659 JULY 2010 Page 5B-5

Power Trim
Power Trim General Information

General Information
The power trim system consists of an electric motor, pressurized fluid reservoir, pump, and trim cylinder.
Trim outboard through entire trim and tilt range several times to remove any air from the system.
The remote control or trim panel is equipped with a switch that is used for trimming the outboard up or down, for tilting the outboard
for shallow water operation at slow speeds, or for trailering. The outboard can be trimmed up or down while engine is under power
or when engine is not running.
Power Trim Operation

With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of
the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an improvement
in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control
hazards.
The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque
results from the outboard being trimmed so the propeller shaft is not parallel to the water surface.
! 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.
Consider the following lists carefully.

1. Trimming in or down can:
Lower the bow
Result in quicker planing off, especially with a heavy load or a stern heavy boat
Generally improve the ride in choppy water
Increase steering torque or pull to the right (with the normal righthand rotation propeller)
In excess, can lower the bow of some boats to a point where they begin to plow with their bow in the water while on
plane. This can result in an unexpected turn in either direction (called bow steering or oversteering) if any turn is
attempted, or if a significant wave is encountered.
! WARNING
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.
Page 5B-6 90-8M0047659 JULY 2010

Power Trim
If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to
your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways, and trailer
bouncing.
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.

BLK Black BLU Blue
BRN Brown GRY Gray
RED Red TAN Tan
90-8M0047659 JULY 2010 Page 5B-7

Power Trim
Power Trim Flow Diagrams

Trim Up Circuit
b
a
j l
d i k
v
h
e
u
m n
f
g
t g
z p
y
s r q
22393
Page 5B-8 90-8M0047659 JULY 2010

Power Trim
a- Trim rod n- Up circuit pressure operated valve
b- End cap o- Manifold reverse suction valve
c- Electric motor p- Manual release valve
d- Reservoir oil q- Manifold
e- Down circuit pressure relief valve r- Tilt relief valve
f- Down circuit pressure operated valve s- Tilt relief piston
g- Filter (two shown for clarity) t- Memory piston
h- Shock return valve u- Shock piston
i- Up circuit suction port v- Impact relief valve
j- Oil pump gears w- Cylinder
k- Down circuit suction port x- Return oil
l- Oil fill cap y- Oil under pressure
m- Shuttle valve z- Filtered supply oil
When the trim switch is activated in the up position, the electric motor begins to rotate the pump gears, and the oil pump draws a
small amount of oil through the filter and through the up circuit suction port. The oil pump gear rotation forces oil into the passages
for the up circuit. Oil under pressure slides the shuttle valve against the down circuit pressure operated valve. The shuttle valve
mechanically opens the down pressure operated valve, allowing oil from the down cavity of the trim cylinder to flow into the oil
pump. This oil returning from the down cavity supplies most of the oil required for the up circuit. Oil in the up circuit is blocked from
returning into the reservoir by the ball inside the down circuit suction port. The pressure of the oil forces the up circuit pressure
operated valve to open, allowing the oil to enter the passages inside the manifold leading to the trim cylinder up cavity. Oil is
blocked from all other passages by the closed manual release valve. Oil under pressure enters the trim cylinder below the memory
piston. With an increasing amount of oil entering the cylinder, the memory and shock pistons force the trim rod up and out, raising
the outboard engine. Oil on the top of the shock piston exits through a passage running down along the side of the cylinder and
enters the manifold passages. The oil is drawn back into the pump through the open down pressure operated valve and enters
the pump as supply for the up circuit.
The trim cylinder positions the outboard at the desired trim angle in the 20 maximum trim range. The system will not allow the
outboard to be trimmed above the 20 trim range as long as the engine RPM is above approximately 2000 RPM.
The outboard can be trimmed above the 20 maximum trim angle for shallow water operation by keeping the engine RPM below
2000. If the RPM increases over 2000, and the propeller is deep enough, propeller thrust causes the trim system to return the
outboard to the 20 maximum trim position. Refer to Trim Limit, following.
90-8M0047659 JULY 2010 Page 5B-9

Power Trim
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
Page 5B-10 90-8M0047659 JULY 2010

Power Trim
In the up mode, as the trim rod extends from the cylinder, the memory piston clears or uncovers the pressure relief passage. Oil
from the up cavity enters this passage and, if required, causes the tilt relief piston to open the tilt pressure relief valve. This valve
lowers the amount of pressure available to lift the outboard motor. With the engine in forward gear, and at high RPM, the oil
pressure available cannot overcome the propeller thrust, limiting the trim range to below the pressure relief passage. Up pressure
flows into the trim relief passage and returns back into the reservoir. When the engine RPMs fall, or if engine is not in forward
gear, oil pressure is available to extend the trim rod up into the tilt range.
90-8M0047659 JULY 2010 Page 5B-11

Power Trim
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
Page 5B-12 90-8M0047659 JULY 2010

Power Trim
With the cylinder at maximum travel, due to no ram movement, the pressure inside of the trim cylinder increases to the pressure
setting of the tilt relief valve. Pressure forces the tilt relief actuator to move and unseat the tilt relief valve allowing oil to return to
the reservoir through passages in the manifold. Oil flow continues until the up button is released.
90-8M0047659 JULY 2010 Page 5B-13

Power Trim
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
Page 5B-14 90-8M0047659 JULY 2010

Power Trim
When the trim switch is activated in the down position, the electric motor rotates the oil pump gears in the opposite direction. With
the oil pump gears rotating backwards, the flow of oil is reversed. Oil is drawn through the filter, through the down circuit suction
port, and into the oil pump gears. The pump forces pressurized oil into the down passages. Oil slides the shuttle valve into the up
circuit pressure operated valve. The shuttle valve mechanically opens the up circuit pressure operated valve and allows oil from
the up cavity of the trim cylinder to return into the oil pump. This oil, returning from the up cavity, supplies the oil required for the
down circuit. The oil is blocked from returning into the reservoir by the ball inside the up circuit suction port. Oil, under pressure,
opens the down circuit pressure operated valve and enters the down passages inside of the manifold. The manifold passage
connects into the trim cylinder passage leading to the top of the cylinder. The cavity inside the cylinder above the shock piston is
the down cavity. As the down cavity fills with oil, the trim rod retracts into the cylinder, lowering the outboard motor. Oil from the
up cavity exits the cylinder and is drawn back into the pump through the open up circuit pressure operated valve. When the trim
rod reaches full travel, the oil pressure inside the down circuit rises until the down circuit pressure relief valve opens, bypassing
oil back into the reservoir. When the trim button is released, the pump stops supplying oil, both of the pressure operated valves
close and, if open, the down circuit pressure relief valve closes. The closed valves locks the fluid on either side of the shock piston
and memory piston, holding the outboard motor in position.
90-8M0047659 JULY 2010 Page 5B-15

Power Trim
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
Page 5B-16 90-8M0047659 JULY 2010

Power Trim
m- Shuttle valve
Oil inside the down cavity is locked in a static position by the closed down circuit pressure operated valve, the manual release
valve, and the manifold reverse suction valve. If the outboard strikes an underwater object while in forward gear, the trim rod tries
to rapidly extend from the cylinder, increasing the pressure inside the trim cylinder down cavity and connecting passages. When
the pressure increases to the relief valve setting, the impact relief valves located inside the shock piston open and allows the fluid
to pass through the shock piston. As the fluid passes through the piston, the trim rod extends from the trim cylinder. The memory
piston remains held in position by vacuum created by the oil in the up cavity being locked in a static position.
90-8M0047659 JULY 2010 Page 5B-17

Power Trim
Shock Function Return
b
a
v
h
j l
y d i k
t e
m n
f
g
g
o
p
x
s r q
22398
Page 5B-18 90-8M0047659 JULY 2010

Power Trim
m- Shuttle valve
After the engine clears the underwater object, the weight of the engine increases the oil pressure between the memory piston and
shock piston to the level required to open the shock return valve inside the shock piston. This allows the oil to bleed back through
the shock piston into the down cavity. If required, additional oil enters the down cavity through the manifold reverse suction valve.
This returns the engine back against the memory piston and into the original running position.
90-8M0047659 JULY 2010 Page 5B-19

Power Trim
Manual Tilt
v
h
u
j l
d i k
t e
m n
f
g
g
o
p
x
s r q
22399
Page 5B-20 90-8M0047659 JULY 2010

Power Trim
a- Trim rod m- Shuttle valve
b- End cap n- Up circuit pressure operated valve
c- Electric motor o- Manifold reverse suction valve
d- Reservoir oil p- Manual release valve
e- Down circuit pressure relief valve q- Manifold
f- Down circuit pressure operated valve r- Tilt relief valve
g- Filter (two shown for clarity) s- Tilt relief piston
h- Shock return valve t- Memory piston
i- Up circuit suction port u- Shock piston
j- Oil pump gears v- Impact relief valve
k- Down circuit suction port w- Cylinder
l- Oil fill cap x- Return oil
To manually tilt the outboard engine, back out the manual release valve 34 turns. With the valve backed out, the internal passages
inside the manifold are connected. These passages connect both the cylinder down and up cavities, along with the reservoir,
allowing the engine to be raised or lowered. Trim rod movement continues until the manual release valve is closed, locking the
fluid inside of the cylinder and manifold. If the outboard motor is to be raised manually, turn the manual release valve
counterclockwise to the full out position. When in the full out position, oil in the trim cylinder can flow freely from the up side to the
down side, or from the down side to the up side. The oil return line into the reservoir is also open, allowing free oil flow to either
side of the tilt cylinder to accommodate the differential oil capacities between the tilt cylinder up side and down side cavities.
When trimming the outboard in either the up or down position, with the manual tilt valve open or leaking, little or no movement
occurs. Oil pressure from the pump moves to both the up cavity, and through the manual tilt valve into the down cavity. There is
equal pressure in each cavity resulting in little or no movement.
IMPORTANT: Do not operate the outboard or trim the outboard in either the up or down direction with the manual tilt valve open.
Damage to the Orings may occur. Close the manual release valve before operating the trim or the outboard.
90-8M0047659 JULY 2010 Page 5B-21

Power Trim
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
Page 5B-22 90-8M0047659 JULY 2010

Power Trim
When the weight of the outboard and propeller thrust reach sufficient levels, the pressure inside the trim cylinder increases to the
pressure required to move the tilt relief piston. The tilt relief piston pin opens the tilt relief valve. Up pressure flows into the trim
relief passage, and returns back into the reservoir. If the outboard engine is positioned in the tilt range (beyond full trim position)
when the tilt relief valve opens, it will move back down to the full trim position (trim limit).
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.
Hydraulic System Troubleshooting

Condition/Problem
Condition of Trim System Problem
Trim motor runs; trim system does not move up or down 1, 2, 5, 6, 9
Does not trim full down. Up trim OK. 2, 3, 4, 6
Does not trim full up. Down trim OK. 1, 2, 4, 6
Partial or jerky down/up 1, 3
Thump noise when shifting 2, 3, 5
Does not trim under load 2, 5, 7, 8, 9, 11
Does not hold trim position under load 4, 5, 6
90-8M0047659 JULY 2010 Page 5B-23

Power Trim
Condition of Trim System Problem

Trail out when backing off from high speed 3, 4
Leaks down and does not hold trim 4, 5, 6
Trim motor working hard and trims slow up and down 7, 8
Trims up very slow 1, 2, 7, 8
Starts to trim up from full down position when the down trim button is depressed 3, 4
Trim position will not hold in reverse 2, 3, 4, 5, 12
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.
Power Trim Electrical System Troubleshooting

General Checks
Before troubleshooting the power trim electrical system, check the following:
Disconnected wires
Connections are tight and corrosion free
Plugin connections are fully engaged
Battery is fully charged
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
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.
Page 5B-24 90-8M0047659 JULY 2010

Power Trim

5. Internal motor problem (brushes, shorted armature) Check for an open connection. Replace the motor.
6. Trim switch failure Replace the switch.
Verify that all relays are functioning correctly. Check the voltage
7. Relay not operating
at the trim bullets.
Power Trim Relay Test Procedure

NOTE: To remove the power trim relays, insert a flat blade screwdriver in the relay lock tab. Gently twist the blade and pry the
relay connector loose. Pull the relay connector out. Do not pull with the wires.
b c a- Main power relay

a
b- Up relay
c- Down relay
d- Flat blade screwdriver
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.
Meter Test Leads Meter Scale Reading ()

Red Black
Green Ground Auto < 20
Blue Ground Auto < 20
3. Replace the relay that does not have continuity.
4. Connect a voltmeter to the heavy blue lead and to ground. There should be 12 volts on the blue lead when the up switch is
pushed and 12 volts on the green lead when the down switch is pushed. Replace the relay that does not switch the lead to
positive.
Meter Test Leads Meter Scale Test Condition Reading (VDC)

Red Black
Blue Ground DC volts Up switch pushed 12 volts
Green Ground DC volts Down switch pushed 12 volts
90-8M0047659 JULY 2010 Page 5B-25

Power Trim
Power Trim Electrical Circuit
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
Troubleshooting the Down Circuit

NOTE: Refer to the preceding wiring diagrams for connection points when troubleshooting the electrical systems. Connection
points are specified by number.
Page 5B-26 90-8M0047659 JULY 2010

Power Trim
Step Test Procedure Test Result

Battery voltage measured:
Disconnect the down relay and 2 pin relay Reconnect the down trim relay.
Step 1: Check for
connector. Connect the voltmeter red lead Go to Step 2.
battery voltage at
to point 1 and black lead to ground. Depress
point 1. No battery voltage measured:
the cowl down tilt switch.
Go to Step 3.

Go to Step 5.
Step 2: Check for No battery voltage measured:

Connect the voltmeter red lead to point 3
battery voltage at There is an open circuit between point 3 and the positive
and the black lead to ground.
point 3. (+) battery terminal.
Check for loose or corroded connections.
Check the wires for an open circuit.

Disconnect the 3 pin cowl switch connector. A wire is open between points 4 and 1.
Step 3: Check for
Connect the voltmeter red lead to point 4 No battery voltage measured:
battery voltage at
and the black lead to ground. Depress the
point 4. Reconnect the 3 pin connector.
trim down switch.
Go to Step 4.

The trim switch is faulty.
battery voltage at
and the black lead to ground. Check for a loose or corroded wire at point 5.
point 5.
There is an open circuit in the wire supplying current to
point 5.

Reconnect the 2 pin relay connector.
Step 5: Check for Go to Step 6.
battery voltage at
(female bullet connector) and the black lead No battery voltage measured:
point 2.
to ground. Depress the down trim button. The relay is defective. Replace the relay.
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.
Troubleshooting the Up Circuit

NOTE: Refer to the preceding wiring diagrams for connection points when troubleshooting the electrical systems. Connection
points are specified by number.
90-8M0047659 JULY 2010 Page 5B-27

Power Trim
Step Test Procedure Test Result

Disconnect the up relay and the 2 pin relay Reconnect the up trim relay.
Step 1: Check for
connector. Connect the voltmeter red lead Go to Step 2.
battery voltage at
to point 8 and the black lead to ground.
point 8. No battery voltage measured:
Depress the cowl up tilt switch.
Go to Step 3.

Go to Step 5.

battery voltage at There is an open circuit between point 3 and the positive
and the black lead to ground.
point 3. (+) battery terminal.
Check for loose or corroded connections.
Check wires for an open circuit.

Disconnect the 3 pin cowl switch connector. A wire is open between points 7 and 8.
Step 3: Check for
Connect the voltmeter red lead to point 7 No battery voltage measured:
battery voltage at
and the black lead to ground. Depress the
point 7. Reconnect the 3 pin connector.
trim up switch.
Go to Step 4.

The trim switch is faulty.
battery voltage at
and the black lead to ground. Check for a loose or corroded wire at point 5.
point 5.
There is an open circuit in the wire supplying current to
point 5.

Reconnect the 2 pin relay connector.
Step 5: Check for Go to Step 6.
battery voltage at
and the black lead to ground. Depress the No battery voltage measured:
point 6.
up trim button. The relay is defective. 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.
Troubleshooting the Up and Down Circuits (All Circuits Inoperative)

NOTE: Refer to previous wiring diagram for location of wire connections.
Problem Possible Cause Remedy
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.
Page 5B-28 90-8M0047659 JULY 2010

Power Trim
Problem Possible Cause Remedy

1. Replace the fuse. Locate the cause of the blown
1. The 15 amp fuse is blown.
fuse. Check electrical wiring for a shorted circuit.
2. One of the trim pump motor wires
2. Check the wire connections at point 2 or 6 for
is open between the motor and the
loose or corroded condition.
relays.
Trim switch and cowl switch are both 3. If voltage is present at the connections at point
inoperative. 3. Faulty trim pump motor. 2 or 6 when the appropriate trim button is pressed,
then the motor is faulty. Replace the motor.
4. Check the trim relays. Refer to Power Trim
4. Faulty trim relay.
Relay Test, preceding.
5. A wire is open between the fuse
5. Check for an open connection or a cut wire.
holder and the solenoid.
Trim system operates (motor runs)
The trim or cowl switch is shorted. Replace the trim switch.
without pressing the switches.
Testing the Power Trim System with Test Gauge Kit

Up Pressure Check
IMPORTANT: This test will not locate problems in the trim system. The test will measure system pressure. If minimum pressures
are not obtainable, the trim system requires additional repair.
IMPORTANT: Ensure the battery is fully charged (12 V minimum) before performing the following tests.
1. Tilt the outboard to the full up position and engage the tilt lock lever.
2. Slowly remove the fill plug to bleed pressure from the reservoir.
3. Remove the circlip securing the manual release valve and unscrew the release valve from the trim assembly.
NOTE: A small amount of trim fluid may drip from the manual release valve hole. Place a suitable container under the trim
assembly to collect any leakage.
NOTE: Assemble the test adapter by using an Oring installation tool to position the small Oring onto the adapter, then install
the medium Oring, and lastly the large Oring. Thread the brass fitting into the test adapter securely using Loctite 567 PST
Pipe Sealant on the threads.
91 822778 1 a- Brass fitting

b- Test adapter
c- Large Oring
d- Medium Oring
a b c d e f 7095
e- Small Oring
f- Oring installation tool

Sealant
90-8M0047659 JULY 2010 Page 5B-29

Power Trim
4. Install the test adapter into the manual release valve hole.
a - Test adapter
7098

5. Thread the hose from the test gauge kit into the brass fitting on the adapter.
e a- Brass fitting
b- Test gauge assembly
c- Tilt pin
d- Hose
a d e- Hose (not used)
c
b
7099

6. Reinstall the fill plug.
7. Remove the tilt stop pin from the transom brackets.
8. Run the trim up and disengage the tilt lock lever.
IMPORTANT: Install the tilt pin correctly to prevent transom failure and personal injury.
Page 5B-30 90-8M0047659 JULY 2010

Power Trim
9. Move the outboard in until the hole in the swivel bracket ear aligns with the fourth tilt hole in the transom bracket. Lock the
engine in the trim range by installing a 10 mm (3/8 in.) diameter tilt pin, or two 10 mm (3/8 in.) hardened bolts and nuts, through
the transom brackets and swivel bracket in the hole shown.
a - Fourth tilt pin hole
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.
Down Pressure Check

IMPORTANT: This test will not locate problems in the trim system. The test will measure system pressure. If minimum pressures
are not obtainable, the trim system requires additional repair.
IMPORTANT: Ensure the battery is fully charged (12 V minimum) before performing the following tests.
1. Tilt the outboard to the full up position and engage the tilt lock lever.
2. Slowly remove the fill plug to bleed pressure from the reservoir.
3. Remove the circlip securing manual release valve and unscrew the release valve from the trim assembly.
90-8M0047659 JULY 2010 Page 5B-31

Power Trim
NOTE: A small amount of trim fluid may drip from the manual release valve hole. Place a suitable container under trim
assembly to collect any leakage.
NOTE: Assemble the test adapter by using the Oring installation tool to position the small Oring onto adapter, then the
medium Oring, and lastly the large Oring. Thread the brass fitting into the test adapter securely using Loctite 567 PST Pipe
Sealant on threads.
f 91 822778 3 a- Test adapter

b- Oring installation tool
c- Small Oring (install first)
d- Medium Oring (install second)
a e d c b 7103
e- Large Oring (install last)
f- Brass fitting

Sealant
4. Install the test adapter into the manual release valve hole.
a - Test adapter
7098

5. Thread the hose from the test gauge kit into the brass fitting on the adapter.
e a- Brass fitting
b- Test gauge assembly
c- Tilt pin
d- Hose
a d e- Hose (not used)
c
b
7099

6. Reinstall the fill plug.
Page 5B-32 90-8M0047659 JULY 2010

Power Trim
7. Run the trim up.
8. Disengage the tilt lock lever.
9. Open valve "a" and close valve "b."
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.
Power Trim System Removal

1. Tilt the outboard to the full up position and support with the tilt lock lever.
a - Tilt lock lever
7084
90-8M0047659 JULY 2010 Page 5B-33

Power Trim
2. Disconnect the power trim wire harness and remove Jclips.
a - Jclips
b - Wire harness
a
b
7086
3. Remove the upper trilobe pin.
a - Upper trilobe pin
7088
4. Drive out the upper pivot pin.
a - Upper pivot pin
7089
5. Remove the sacrificial anode.
Page 5B-34 90-8M0047659 JULY 2010

Power Trim
6. Use suitable punch to remove lower trilobe pin.
a - Lower trilobe pin

b - Anode
a
b 23798
7. Use suitable punch to drive out lower pivot pin.
a - Lower pivot pin
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
90-8M0047659 JULY 2010 Page 5B-35

Power Trim
Power Trim Disassembly

Draining Power Trim
IMPORTANT: Power trim system is pressurized. Trim rod must be fully extended in the up position, prior to fill/drain plug, or manual
release valve removal.
1. Remove reservoir plug.
2. Remove manual release valve assembly to drain oil.
a - Reservoir plug
b - Manual release valve
7104
Trim Motor Removal

1. Secure power trim assembly in a soft jaw vise.
2. Remove four screws to detach motor/reservoir. Remove reservoir seal and coupler.
a a- Screw and washer (4)

b- Reservoir
c- Reservoir seal
b d- Coupler
e- Manifold assembly
f- Ground strap
c
e
f
7105
Page 5B-36 90-8M0047659 JULY 2010

Power Trim
Power Trim Pump and Components Removal

1. Remove pressure operated plugs on pump. Remove spring and check valve/poppet from both sides. Use an expanding rod
and collet to remove check valve/poppet.
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
Expanding Rod Snap On CG4111

Collet Snap On CG4114
2. Inspect poppet assembly for debris in the area shown. If debris is found on poppet, replace poppet.
a - Debris under valve

b - Rubber seat
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
90-8M0047659 JULY 2010 Page 5B-37

Power Trim
Manifold Removal
1. Remove two screws to remove manifold from cylinder.
a - Screw (2)
a 7114
2. Remove tilt relief components.
a- Spring
b- Poppet
c- Spool housing
d- Trim limit spool
a
b
d 7113
51146
Shock Rod Removal

1. Unscrew end cap assembly from cylinder using spanner wrench 6.4 mm x 8 mm (1/4 in. x 5/16 in.) long pegs.
2. Remove shock rod assembly from cylinder.
7115

Page 5B-38 90-8M0047659 JULY 2010

Power Trim
Shock Rod Disassembly

NOTE: The only serviceable items on the shock rod assembly are the Orings and wiper ring. If the shock rod requires any other
repair, replace the shock rod assembly.
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
90-8M0047659 JULY 2010 Page 5B-39

Power Trim
5. Place the shock rod into a soft jawed vise and apply heat to loosen the piston using a torch lamp.
51146
12884
Torch Lamp 91 63209

6. Loosen the shock rod piston using a spanner wrench (6.4 mm x 8 mm [1/4 in. x 5/16 in.] long pegs).
IMPORTANT: Use a spanner wrench with 6.4 mm x 8 mm (1/4 in. x 5/16 in.) long pegs to remove the shock rod piston.
NOTE: When using the trim cylinder end cap tool, use the large diameter pins, 5.97 mm (0.235 in.), in the 1 in. span position.
Pins should be partially pulled out of the spanner wrench to extend approximately 9.5 mm (0.375 in.).
a - Spanner wrench
b b - Shock rod piston
7121

7. Allow the shock rod piston to cool. Remove from the shock rod.
8. Inspect the check valve for debris. Clean debris from the check valve if found. If debris cannot be cleaned from the check
valve, replace the shock piston as an assembly.
9. Clean the shock and components with compressed air.
Page 5B-40 90-8M0047659 JULY 2010

Power Trim
10. Remove the inner Oring from the shock rod piston.
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
Memory Piston Removal

1. Remove the memory piston from the cylinder using one of two methods:
a. Use lockring pliers or suitable tool.
a - Lockring pliers
7127
Lockring Pliers SnapOn SRP4
90-8M0047659 JULY 2010 Page 5B-41

Power Trim
b. Blow compressed air into the manual release valve hole using an air nozzle.
! 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
Power Trim Cleaning, Inspection, and Repair

IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in the power trim system could cause system to
malfunction.
1. Clean shock rod and components with parts cleaner and dry with compressed air.
NOTE: It is recommended that all Orings in trim system be replaced. Use Oring kit 25809880A1.
2. Lubricate all Orings with Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).

Fluid
Page 5B-42 90-8M0047659 JULY 2010

Power Trim
Trim Motor Electrical Tests

Connect a 12 volt supply to motor leads. If motor fails to run, replace pump motor.
7132
IMPORTANT: Trim motor is not serviceable. If motor fails to run, replace motor assembly.
90-8M0047659 JULY 2010 Page 5B-43

Power Trim
Power Trim Assembly

ORing and Seal Placement
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
Page 5B-44 90-8M0047659 JULY 2010

Power Trim
O-Ring and Seal Placement

ORing Description ORing I.D. ORing O.D. ORing Width
1 Wiper ring
2 Inner cylinder cap 17.04 mm (0.671 in.) 24.10 mm (0.949 in.) 3.53 mm (0.139 in.)
3 Cylinder cap 47.34 mm (1.864 in.) 50.90 mm (2.004 in.) 1.78 mm (0.07 in.)
4 Shock piston 40.64 mm (1.6 in.) 53.086 mm (2.02 in.) 5.334 mm (0.21 in.)
5 Piston screw 17.17 mm (0.676 in.) 20.726 mm (0.816 in.) 1.78 mm (0.07 in.)
6 Reservoir plug 13.94 mm (0.549 in.) 19.17 mm (0.755 in.) 2.616 mm (0.103 in.)
7 Motor seal
8 P.O. check plug 12.42 mm (0.489 in.) 15.97 mm (0.629 in.) 1.78 mm (0.07 in.)
9 Poppet assembly
10 P.O. check seat 9.25 mm (0.364 in.) 12.80 mm (0.504 in.) 1.78 mm (0.07 in.)
11 Pump port 3.683 mm (0.145 in.) 7.239 mm (0.285 in.) 1.78 mm (0.07 in.)
12 Suction seat 6.07 mm (0.239 in.) 9.626 mm (0.379 in.) 1.78 mm (0.07 in.)
13 Filter seal
14 Filter
15 Manual release 2.90 mm (0.114 in.) 6.451 mm (0.254 in.) 1.78 mm (0.07 in.)
18 Spool 6.07 mm (0.239 in.) 9.626 mm (0.379 in.) 1.78 mm (0.07 in.)
19 Spool housing 7.645 mm (0.301 in.) 11.20 mm (0.441 in.) 1.78 mm (0.07 in.)
20 Trim limit spool 2.895 mm (0.114 in.) 6.451 mm (0.254 in.) 1.78 mm (0.07 in.)
21 Manifold 5.283 mm (0.208 in.) 8.839 mm (3.48 in.) 1.78 mm (0.07 in.)
22 Memory piston 40.64 mm (1.6 in.) 53.086 mm (2.02 in.) 5.334 mm (0.21 in.)
90-8M0047659 JULY 2010 Page 5B-45

Power Trim
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
Page 5B-46 90-8M0047659 JULY 2010

Power Trim
Shock Rod Assembly

IMPORTANT: Lubricate all Orings with Power Trim and Steering Fluid. If not available, use automotive automatic transmission
fluid (ATF).

Fluid
1. Install the lubricated Orings to the end cap.
d
a- Rod wiper
b- Cylinder end cap
c c- Inner Oring
d- Outer Oring
b
7126
2. Install the rod wiper.

3. Install the lubricated Orings to the shock piston.
a - Shock piston
b - Oring
b
7125
4. Clamp the shock rod in a soft jawed vise.
90-8M0047659 JULY 2010 Page 5B-47

Power Trim
5. Position the trim cylinder end cap onto the rod, as shown.
a a - Trim cylinder rod

b - Trim cylinder end cap
7137
6. Apply Loctite 271 Threadlocker to the threads on the shock rod.

7 Loctite 271 Threadlocker Shock rod threads 92-809819
7. Install the shock rod piston.
IMPORTANT: Use a spanner wrench with 6.4 mm x 8 mm (1/4 in. x 5/16 in.) long pegs to remove the shock rod piston.
8. Tighten the shock rod piston securely using a 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 shock rod piston, then tighten to the specified torque.
NOTE: When using the trim cylinder end cap tool, use the large diameter pins, 5.97 mm (0.235 in.), in the 1 in. span position.
Pins should be partially pulled out of the spanner wrench to extend approximately 9.5 mm (0.375 in.).
a - Spanner wrench
b b - Shock rod piston
7121


Shock rod piston 122 90
9. Remove the shock rod assembly from the vise.
Page 5B-48 90-8M0047659 JULY 2010

Power Trim
10. Install the ball, seat, and spring (five sets) to the shock rod piston. Install Oring onto the shock rod piston.
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

Screw 4 35
Shock Rod Installation

1. Place the trim cylinder in a soft jawed vice.
2. Install lubricated Oring to the memory piston and place into the cylinder. Push memory piston all the way to bottom.
3. Fill cylinder 75 mm (3 in.) from top of cylinder using Power Trim and Steering Fluid. If not available, use automotive automatic
transmission fluid (ATF).

114 Power trim system 92-858074K01
Fluid
90-8M0047659 JULY 2010 Page 5B-49

Power Trim
4. Install the shock rod into the cylinder until power trim fluid flows through the oil blow off ball passage. Fill remaining cylinder
to just below the cylinder threads.
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.


End cap 61 45
Trim Limit Installation

Lubricate all Orings. Install spring, poppet, spool housing, and trim limit spool into manifold.
NOTE: There are three different size springs used in this manifold. The heavy spring is used on 75125 hp outboards. The medium
spring is used on 4060 hp BigFoot outboards. The light spring is used on 3060 hp outboards.
a- Spring
b- Poppet
c- Spool housing
d- Trim limit spool
a
b
d 7113
51146
Manual Release Valve Installation

1. Install Eclip (if removed) and lubricate Orings on manual release valve.
Page 5B-50 90-8M0047659 JULY 2010

Power Trim
2. Install manual release valve assembly into manifold.
a
a - Manifold
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.
a - Trim cylinder assembly

a b - Reservoir/manifold assembly
b 11023
90-8M0047659 JULY 2010 Page 5B-51

Power Trim
3. Install the two long screws and tighten to the specified torque.
a - Screw (2)
a 7114

Trim cylinder screw 11.3 100
Power Trim Pump and Components Installation

Pump Installation
1. Install spring, ball, lubricated Oring, and plastic seat into manifold.
2. Check to see that Orings are placed on bottom of pump.
3. Install filter and filter seal under the pump. Install pump onto manifold. Tighten screws to specified torque.
a a- Screw (3)
b- Filter seal
c- Filter
d- Suction seat assembly
7111

Fluid

Screw 8 70
Page 5B-52 90-8M0047659 JULY 2010

Power Trim
Pressure Operated Plugs

IMPORTANT: Inspect poppet assembly for debris in the area shown. If debris is found on poppet, replace poppet.
a - Debris under valve

b - Rubber seat
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

Fluid

Plug 13.5 120
Trim Motor Installation

1. Install the coupler into the top of the pump.
2. Make sure that the reservoir seal is in the reservoir groove. Place the reservoir onto the manifold assembly.
90-8M0047659 JULY 2010 Page 5B-53

Power Trim
3. Install the ground strap under the screw shown. Tighten the screws to the specified torque.
a a- Screw and washer (4)

b- Reservoir
c- Reservoir seal
b d- Coupler
e- Manifold assembly
f- Ground strap
c
e
f
7105

Reservoir/manifold screw 9.6 85
4. Fill the reservoir to bottom of the fill hole using Power Trim and Steering Fluid. If not available, use automotive automatic
transmission fluid (ATF).

Fluid
Bleeding Power Trim Unit

1. Secure the power trim unit in a soft jawed vise.
2. Add Power Trim and Steering Fluid until it is even with the bottom of the fill hole. Install plug.

Fluid
3. Close the manual release valve. Turn full clockwise.
a - Reservoir plug
7104
Page 5B-54 90-8M0047659 JULY 2010

Power Trim
Direction Color Charge

Blue Positive (+)
Up
Green Negative ()
Blue Negative ()
Down
Green Positive (+)
4. Connect power trim wire to 12 volt source.
5. Cycle system full up and down three times or until fluid level remains at proper level.
6. Recheck fluid level with rod fully extended, add fluid if required and repeat cycle until fluid level stays even with the bottom
of the fill hole.
Power Trim System Installation

1. Apply 24C with Teflon to lower pivot pin bore and pivot pin surface.

95 2-4-C with Teflon Pivot pin surface and lower pivot pin bore 92-802859A 1
2. Position trim cylinder assembly, bottom first, between clamp brackets and route trim pump electrical harness through access
hole in starboard clamp bracket.
3. Start lower pivot pin into pivot pin bore and position lower cross pin retained during disassembly in its respective hole.
a - Trim cylinder assembly

b - Lower pivot pin
c - Lower cross pin
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 - Lower cross pin

b - Sacrificial anode
c - Ground strap
a
c
b 7145
7. Apply 24C with Teflon to surface of upper pivot pin, pivot pin bore, and trim ram bore.
90-8M0047659 JULY 2010 Page 5B-55

Power Trim
NOTE: Install trim ram with cross hole located as shown. If trim ram is installed reversed, the trim sender will not operate.
a- Pivot pin
b- Trim ram bore
c- Cross hole
d- Transom side
b e- Engine side
a c
7146

95 2-4-C with Teflon Upper pivot pin and bore, trim ram bore 92-802859A 1
8. Using a suitable mallet, drive upper pivot pin into swivel bracket and through trim ram until pivot pin is flush with swivel bracket.
a - Pivot pin
b - Swivel bracket
c - Trim ram
b
a c
7152
Page 5B-56 90-8M0047659 JULY 2010

Power Trim
9. Drive upper trilobe pin in until seated.
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.
90-8M0047659 JULY 2010 Page 5B-57

Power Trim
Notes:
Page 5B-58 90-8M0047659 JULY 2010

Gear Housing
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
90-8M0047659 JULY 2010 Page 6A-1

Gear Housing
Gear Housing Specifications

Model 75/90 Gear Housing Specifications
Gear ratio 2.33:1
Normal temperature and when poppet valves open 1. 1800 RPM
Model 115/115 Pro XS/125 Gear Housing Specifications

Gear ratio 2.07:1
Normal temperature and when poppet valves open1. 1800 RPM

Pinion nut, shift shaft seal outside diameter, water pump base
screws, water pump cover screws, driveshaft seal ring
Outside diameter of propeller shaft seals, bearing carrier retaining
studs
Outside diameter of bearing carrier seal
Outside diameter of seal
Outside diameter of driveshaft rubber ring
7 Loctite 271 Threadlocker Outside diameter of shift shaft seal 92-809819
Threads of the shift shaft bushing screws
Pinion nut threads
Outside diameter of water pump upper seal
Outside diameter of lower water pump seal
Water pump base screw threads
Water pump cover screw threads
Threads of gear housing retaining screws
1. After the poppet valve opens at approximately 1800 RPM, the engine temperature will drop to 2738 C (80100 F).
Page 6A-2 90-8M0047659 JULY 2010

Gear Housing

Gearcase
Inside diameter of forward gear and outside diameter of needle
bearing
87 Thrust washers 92-858064K01
Lubricant
Thrust bearing
Reverse gear bearing surface
Gear housing
Shift shaft O-ring, inside diameter of all seals, driveshaft splines
Inside diameter of propeller shaft seals, bearing carrier, cam
follower
Outside diameter of forward gear bearing race
Inside diameter of bearing
Outside diameter of needle bearing and bearing carrier bore
O-ring and seal lips; outside diameter of reverse gear bearing and
bearing carrier bore
95 2-4-C with Teflon Outside diameter of bearing race 92-802859A 1
Inside diameter of bearing sleeve and outside diameter of upper
driveshaft bearing
Inside diameter of shift shaft seal and shift shaft bushing O-ring
Bearing carrier and the gear housing mating surfaces
Lip of each seal
Inside diameter of water pump cover
Water tube seal inner diameter
Driveshaft splines and shift shaft splines
RTV 587 Ultra Blue Silicone
116 Water pump exhaust dam 92-809825
Sealer
117 Loctite 7649 Primer N Driveshaft threads and pinion nut threads 92-809824
Special Tools
Puller Jaws Assembly 9146086A1
Removes bearing carrier and bearing races; use with Puller Bolt (9185716).
9514
Slide Hammer 9134569A 1
Aids in the removal of various engine components. Use with puller jaws.
6761
90-8M0047659 JULY 2010 Page 6A-3

Gear Housing
Bearing Removal and Installation Kit 9131229A7

Installs and removes the bearings in all gearcases.
9131229A7 tool assembly includes the following components:
1124156 Hex Nut
1234961 Washer
9115755T Bearing Carrier
9129310 Plate
9129610 Pilot Plate
9130366T1 Mandrel
9131229 Puller Shaft
9132325T Driver Head
9132336 Driver Needle Bearing
9136379 Puller/Head Gear
9136569T Driver Head
9136571T Pilot Washer
9137292 Roller Bearing
2966 9137311 Driver Head
9137312 Driver Head
9137323 Driver Head Rod
9137324 Pilot Washer
9138628T Puller/Driver Head
9152394 Head Pull Rod
Dial Indicator 91 58222A 1

location, and TDC.
9479
Driveshaft Holding Tool 9156775T
Provides a wrench surface to turn the driveshaft. Also used to hold driveshaft for
pinion gear installation.
9448
Removes bearings from gears and the driveshaft.
8505
Bearing Puller Assembly 91 83165T
Removes bearings, races and bearing carriers.
3610
Page 6A-4 90-8M0047659 JULY 2010

Gear Housing
Bearing Race Driver 91 14308T02
Removes pinion bearing race.

8879
Bearing Cup Driver 91 31106T
Installs the driven gear bearing cup.
8882
Pilot Mandrel 91 37350T
Presses on inner race of forward gear roller bearing.

8884
Bearing Driver 91856875A 1
Installs prop shaft needle bearing into 3 jaw or 6 jaw forward gear.
8885
Bearing Installation Driver 91 13945
Installs reverse gear needle bearing into prop shaft carrier.
8877
Driver Rod 91 37323
25431 Aids in the removal and installation of various bearings and bearing races
Oil Seal Driver 91 31108T
Installs bearing carrier oil seals.
8883
Wear Sleeve Installation Tool 9114310T 1
Installs wear sleeve onto driveshaft.

8881
90-8M0047659 JULY 2010 Page 6A-5

Gear Housing
Bearing Removal and Installation Kit 91 31229A 7

Installs and removes the bearings in all gearcases.
91 31229A 7 tool assembly includes the following components:
11 24156 Hex Nut
12 34961 Washer
91 15755T Bearing Carrier
91 29310 Plate
91 30366T 1 Mandrel
91 31229 Puller Shaft
91 32325T Driver Head
9136379 Puller/Head Gear
91 36569T Driver Head
91 36571T Pilot Washer
9137292 Roller Bearing
91 37311 Driver Head
2966 91 37312T Driver Head
91 37323 Driver Head Rod
91 37324T Pilot Washer
91 37350T Pilot Mandrel
91 38628T Puller/Driver Head
9152393T Driver Needle Bearing
9152394 Head Pull Rod
Bearing Installation Puller 91 14309T02
Installs pinion bearing into gearcase.

8880
Bearing Preload Tool 9114311A04
Simulates a load on the driveshaft for accurate pinion height and backlash
measurements.
8756
Pinion Gear Locating Tool 9112349A05
Measures pinion gear height.
3608
Dial Indicator Adapter 9183155
Dial indicator holding fixture

2999
Page 6A-6 90-8M0047659 JULY 2010

Gear Housing
Backlash Indicator 91196601
Measures gear backlash
8757

location, and TDC
9479
Oil Seal Driver 9113949
Installs oil seals into water pump base.
8878
Checks gear housing for leakage prior to filling with gear lubricant.
29497
90-8M0047659 JULY 2010 Page 6A-7

Gear Housing
Gear Housing (Driveshaft)

31
42 21
7
32
29 7
95 22 95
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
Page 6A-8 90-8M0047659 JULY 2010

Gear Housing

Torque
1 1 Gear housing
2 1 Dowel pin
3 1 Oiler tube
5 3 Seal
6 1 Dowel pin
7 1 Trim tab
8 1 Screw (0.43714 x 1.25) 29.8 22
9 1 Washer
10 1 Carrier
11 1 Needle bearing
12 2 Anode
13 1 Nut (M6) 6.8 60
14 1 Screw (M6 x 40) 6.8 60
15 1 Pinion gear
16 1 Nut (0.62518) 95 70
17 1 Shift cam
18 1 Tapered roller bearing
19 AR Shim set
20 1 Driveshaft
21 1 Wear sleeve assembly
22 1 Seal ring
23 1 Water pump base
24 1 Gasket
25 1 Gasket
26 1 Lower oil seal
27 1 Upper oil seal
28 1 Gasket
29 1 Water pump housing
30 1 Face plate
steel face plate 6.8 60
31 4 Screw (M6 x 30)
rubber overmold face plate 8.5 75
32 1 Seal
33 1 Key
34 1 Impeller
35 6 Screw (M6 x 25) 6.8 60
36 1 Shift shaft assembly
37 1 Ering
38 1 Bushing assembly
39 1 Oring
90-8M0047659 JULY 2010 Page 6A-9

Gear Housing
Torque
40 1 Oil seal
41 2 Screw (M6 x 25) 6.8 60
42 1 Face seal

Pinion nut, shift shaft seal outside diameter, water pump base
screws, water pump cover screws, driveshaft seal ring
87 Gearcase 92-858064K01
Lubricant
95 2-4-C with Teflon Shift shaft O-ring, inside diameter of all seals, driveshaft splines 92-802859A 1
RTV 587 Ultra Blue Silicone
Sealer
Page 6A-10 90-8M0047659 JULY 2010

Gear Housing

31
42 21
7
32
29 7
95 22 95
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
90-8M0047659 JULY 2010 Page 6A-11

Gear Housing
Gear Housing (Propeller Shaft)

29
95
1
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
Page 6A-12 90-8M0047659 JULY 2010

Gear Housing
Gear Housing (Propeller Shaft)

Torque
1 1 Gear housing assembly
2 1 Tapered roller bearing assembly
3 1 Cup
4 1 Forward gear
5 1 Needle bearing
6 1 Retaining ring
7 1 Cam follower
8 3 Ball
9 1 Slide
10 1 Spring
11 1 Clutch
12 1 Cross pin
13 1 Spring
14 1 Propeller shaft
15 1 Reverse gear
16 1 Bearing carrier assembly
17 1 Oring
18 1 Needle bearing
19 1 Inner oil seal
20 1 Outer oil seal
21 1 Needle bearing
22 1 Thrust washer
23 1 Thrust bearing
24 2 Stud 135 100
25 2 Washer
26 2 Nut 33.9 25
27 AR Shim
28 2 Thread insert
29 1 Decal
30 1 Drive sleeve
31 1 Adapter
32 1 Locknut

Outside diameter of propeller shaft seals, bearing carrier
retaining studs
Inside diameter of propeller shaft seals, bearing carrier, cam
95 2-4-C with Teflon 92-802859A 1
follower
90-8M0047659 JULY 2010 Page 6A-13

Gear Housing
General Service Recommendations

There may be more than one way to disassemble or reassemble a particular part, therefore, it is recommended that the entire
procedure be read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
In many cases, disassembly of a subassembly may not be necessary, until cleaning and inspection reveals that disassembly is
required for replacement of one or more components.
Service procedure order in this section is a normal disassembly/reassembly sequence. It is suggested that the sequence be
followed without deviation to assure proper repairs. When performing partial repairs, follow the instructions to the point where the
desired component can be replaced, then proceed to reassembly and installation of that component in the reassembly part of this
section. Use the Table of Contents (on back of section divider) to find correct page number.
Threaded parts are righthand (RH), unless otherwise indicated.
Clean surfaces and/or threads with an appropriate solvent before applying Loctite (Mercury Marine recommends using electrical
contact surface cleaner). A primer is not required unless using Loctite 271 Threadlocker.
IMPORTANT: Primer T must be used with Loctite 271 Threadlocker on all brass, cadmiumplated, stainless steel, and instances
where two dissimilar metal surfaces are being joined. Regular steel surfaces do not require a primer, but do require that their
contact surfaces be cleaned using an appropriate solvent.
When holding, pressing, or driving is required, use soft metal vise jaw protectors or wood for protection of parts. Use a suitable
mandrel (one that will contact only the bearing race) when pressing or driving bearings.
Whenever compressed air is used to dry a part, verify that no water is present in air line.
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.
Draining and Inspecting Gear Housing Lubricant

! WARNING
Page 6A-14 90-8M0047659 JULY 2010

Gear Housing
1. Position a clean drain pan under the gear housing. Remove the vent screws and the fill/drain screw with gaskets from the
gear housing.
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.
Gear Housing Removal

1. Shift the engine into forward gear.
2. Tilt the engine to full up position.
! WARNING
3. Remove the four fasteners.
4. Remove the locknut and washer.
a - Fasteners (2 each side)

b - Locknut and washer (recessed)
a
b
7156
5. Remove the gear housing.
90-8M0047659 JULY 2010 Page 6A-15

Gear Housing
Gear Housing Disassembly

Water Pump Disassembly
NOTE: Ensure the water tube seal has been removed from the water tube after gear housing removal.
1. Replace the water tube seal, if damaged.
2. Remove the two screws on each side of the water pump housing. Remove the washers and isolators.
3. Remove the cover.
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.
Page 6A-16 90-8M0047659 JULY 2010

Gear Housing
8. Replace the plate if the grooves, other than the impeller sealing bead groove, are more than 0.75 mm (0.030 in.) deep.
a
a - Plate
c b - Gasket
c - Impeller sealing bead groove
7165
9. Remove the screws and washers.
a - Screws and washers (6)
a
7168
10. Remove the water pump base using flat screwdrivers to lightly pry up on the base.
a
a - Water pump base
7171
90-8M0047659 JULY 2010 Page 6A-17

Gear Housing
11. Remove and discard the seals. Do not scar the seal surface in the water pump base while removing the seals. If the seal
surface is scarred, replace the water pump base.
a - Seals
7173
12. Remove the gasket.
a a - Gasket
7174
Shift Shaft Disassembly

1. Remove the shift shaft bushing attaching screws.
a - Screw (M6 x 25) (2)

a
7206
NOTE: Remove rough edges from shift shaft splines before removing shift shaft bushing.
Page 6A-18 90-8M0047659 JULY 2010

Gear Housing
2. Remove the shift shaft bushing and the shift shaft.
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
Bearing Carrier and Propeller Shaft Removal

1. Ensure the gear housing is in neutral.
90-8M0047659 JULY 2010 Page 6A-19

Gear Housing
2. Remove the locknuts and washers.
a - Locknuts and washers

a
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

6. Remove the reverse gear, thrust bearing, and thrust washer from the bearing carrier.
a - Reverse gear
a b - Thrust bearing
c - Thrust washer
b
7178
Page 6A-20 90-8M0047659 JULY 2010

Gear Housing
7. Clamp the bearing carrier in a vise.

8. Remove the reverse gear roller bearing with a slide hammer and appropriate jaws.
a
a - Roller bearing
7180

9. Remove the oil seals and propeller shaft bearing using a mandrel and driver rod. Discard the oil seals.
a- Propeller shaft bearing

b- Mandrel
c- Driver rod
c d- Oil seals
a
b
21618
Bearing Removal and Installation Kit 9131229A7

10. Remove the bearing carrier Oring.
a - Oring
7187
90-8M0047659 JULY 2010 Page 6A-21

Gear Housing
Propeller Shaft Disassembly

1. Insert a thin blade screwdriver or awl under the first coil of the cross pin retainer spring and rotate the propeller shaft to unwind
the spring from the sliding clutch. Do not overstretch the spring.
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
4. Remove the components from the propeller shaft.
c
a a- Cam follower
b
b- Metal balls (3)
c- Jaws
d- Sliding clutch
e- Guide block
f- Spring
7195
e f
d
Propeller Shaft Inspection

1. Clean propeller shaft with solvent and dry with compressed air.
2. Inspect bearing carrier oil seal surfaces for grooves. Replace shaft if groove is found.
Page 6A-22 90-8M0047659 JULY 2010

Gear Housing
3. Visually check bearing surfaces of propeller shaft for pitting, grooves, scoring, uneven wear, or bluish discoloration from
overheating. Replace shaft and corresponding needle bearing if any of these conditions are found. The bearing carrier needle
bearing contacts propeller shaft just in front of oil seal surface. The forward gear needle bearing contacts propeller shaft in
front of sliding clutch splines.
4. Inspect propeller shaft splines for wear and/or corrosion damage.
5. Check propeller shaft for straightness.
Position propeller shaft roller bearing surfaces on Vblocks. Mount a dial indicator at front edge of propeller splines.
Rotate propeller shaft. Dial indicator movement of more than 0.228 mm (0.009 in.), or a noticeable wobble, is reason
for replacement.
a - Measuring point
b b - Bearing surface
a
29505
Dial Indicator 91 58222A 1

6. Replace propeller shaft if any of the following exist:
Splines are twisted or worn.
Bearing surfaces of propeller shaft are pitted or worn.
Oil seal surface is grooved.
Shaft has a noticeable wobble or is bent more than 0.228 mm (0.009 in.). Propeller shaft trueness should be measured
with a dial indicator with the propeller shaft on Vblocks.
7. Inspect sliding clutch jaws for damage. Jaws must not be chipped or rounded off. Replace the clutch if damaged. Rounded
jaws indicate one or more of the following:
Improper shift cable adjustment.
Improper shift habits of operators. Shifting from neutral to reverse gear too slowly.
Engine idle speed too high while shifting.
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.
Pinion Gear, Driveshaft, and Forward Gear Removal

1. Hold the driveshaft using the driveshaft holding tool. Remove and discard the pinion nut.
90-8M0047659 JULY 2010 Page 6A-23

Gear Housing
2. Remove the driveshaft, pinion gear, lower tapered driveshaft bearing, and forward gear.
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

3. Use a suitable tool to remove the retaining ring.
a
a - Retaining ring
29506
4. Use a punch and hammer to remove the forward gear needle bearing.
a - Forward gear needle bearing
a 7198
Page 6A-24 90-8M0047659 JULY 2010

Gear Housing
5. Remove the forward gear roller bearing from the gear using a universal puller plate and mandrel.
a c a - Forward gear roller bearing

b - Universal puller plate
c - Mandrel
b 28155

6. Install the universal puller plate onto the driveshaft wear sleeve.
7. Support the universal puller plate in a vise. Do not tighten the vise onto the driveshaft.
8. Remove and discard the sleeve.
e
a- Driveshaft splines
b- Bearing surface
c- Wear sleeve
a d- Universal puller plate
e- Mallet
c
d
b
a 21538

9. Remove and discard the rubber ring.
a
a - Rubber ring
7200
90-8M0047659 JULY 2010 Page 6A-25

Gear Housing
Upper Driveshaft Bearing Removal

1. Replace upper driveshaft bearing and sleeve if either are rust stained, or if bearing will not roll freely.
2. Remove bearing and then sleeve using puller assembly with suitable jaws.
a - Upper driveshaft bearing

b - Sleeve
c - Puller assembly
c
b 7201
Oil Sleeve Removal

IMPORTANT: The upper driveshaft bearing and sleeve must be removed prior to oil sleeve removal. Refer to Upper Driveshaft
Bearing Removal.
Remove oil sleeve, if necessary, using puller assembly with suitable jaws.
a - Oil sleeve
b - Puller assembly
b
7202
Lower Driveshaft Bearing Race Removal

IMPORTANT: Upper driveshaft bearing/sleeve and oil sleeve do not have to be removed for lower driveshaft bearing race removal.
IMPORTANT: Retain shims for reassembly.
Page 6A-26 90-8M0047659 JULY 2010

Gear Housing
Remove race and shims using bearing race tool.
a - Bearing race
b - Shim
c - Bearing race tool
a
c
7203
Bearing Race Driver 91 14308T02
Forward Gear Bearing Race Removal

IMPORTANT: Retain shims for reassembly. If shims are damaged, replace with new shims of equal thickness.
Remove race and shims using slide hammer.
a a - Race
b - Shims
c - Slide hammer
b c
7211
Gear Housing Assembly

Forward Gear Bearing Race Assembly
NOTE: Propeller shaft should be vertical when installing bearing race.
1. Place shims retained from disassembly into housing. If shims were lost, or a new gear housing is used for reassembly, start
with 0.254 mm (0.010 in.) shim.
2. Assemble components, as shown, using bearing cup driver. Apply 24C with Teflon to outside diameter of race. Drive race
into housing by striking propeller shaft end with a dead blow hammer.
90-8M0047659 JULY 2010 Page 6A-27

Gear Housing
NOTE: Install a nut on the end of the propeller shaft to prevent damage to the threads while performing step 2.
a- Shims
e b- Race
d c c- Bearing cup driver
d- Disassembled propeller shaft
a e- Assembled bearing carrier
b 7212
Bearing Cup Driver 91 31106T

95 2-4-C with Teflon Outside diameter of forward gear bearing race 92-802859A 1
Forward Gear Assembly

1. Apply 24C with Teflon to the inside diameter of the bearing. Press bearing onto gear using suitable mandrel. Press only on
inner race of bearing. The gear hub is longer than the bearing and you must use a tube type mandrel to install the bearing.
This will allow the bearing to bottom out on the gear.
a - Mandrel
a b - Bearing
7235
Pilot Mandrel 91 37350T

95 2-4-C with Teflon Inside diameter of bearing 92-802859A 1
2. Replace the forward gear needle bearing with the forward gear bearing installer tool. The 6 jaw clutch requires the forward
gear needle bearing be installed with the nonstepped side of the forward gear bearing installer tool.
a a - Nonstepped side of tool

b - Numbered end of needle bearing
c - 6 jaw reverse clutch
c b 7239
Page 6A-28 90-8M0047659 JULY 2010

Gear Housing

3. Apply High Performance Gear Lubricant to inside diameter of forward gear and outside diameter of needle bearing. Press
the needle bearing into the forward gear until the tool bottoms out on the gear.
a - Needle bearing
b b - Forward gear bearing installer
a
7236

High Performance Gear Inside diameter of forward gear and outside diameter of
87 92-858064K01
Lubricant needle bearing
4. Install retaining ring into groove of forward gear by starting at one end of retaining ring and working it around until seated in
groove.
a
a - Retaining ring
29506
Bearing Carrier Assembly

1. Lubricate outside diameter of bearing and bearing carrier bore with 24C with Teflon.
2. Protect lip on forward side of bearing carrier, using bearing installation tool.
90-8M0047659 JULY 2010 Page 6A-29

Gear Housing
3. Press propeller shaft needle bearing, numbered side toward mandrel, into carrier until bearing bottoms out.
a - Bearing installation tool

b - Mandrel
c - Driver rod
7224

Driver Rod 91 37323

95 2-4-C with Teflon Outside diameter of needle bearing and bearing carrier bore 92-802859A 1
4. Place smaller diameter seal on longer shoulder of oil seal driver with seal lip away from shoulder.
5. Protect lip on front side of bearing carrier using bearing installation driver. Apply Loctite 271 Threadlocker on the outside
diameter of seal. Press seal into carrier until tool bottoms.
a a - Seal
b - Oil seal driver
b c - Bearing installation driver
7225

Page 6A-30 90-8M0047659 JULY 2010

Gear Housing

7 Loctite 271 Threadlocker Outside diameter of bearing carrier seal 92-809819
6. Place larger diameter seal on shorter shoulder of oil seal driver with seal lip toward shoulder.
7. Protect lip on front side of bearing carrier using bearing installation tool. Apply Loctite 271 Threadlocker on outside diameter
of new seal. Press seal into carrier until tool bottoms.
a - Bearing installation tool

b - Seal
c - Oil seal driver
b
c
7228


7 Loctite 271 Threadlocker Outside diameter of seal 92-809819
8. Install Oring. Lubricate Oring with 24C with Teflon. Lubricate seal lips with 24C with Teflon.
9. Lubricate outside diameter of reverse gear bearing and bearing carrier bore with a light coating of 24C with Teflon.
10. Press bearing into carrier until tool bottoms.
a - Oring
b - Bearing
b c - Bearing installation tool
c
7230
90-8M0047659 JULY 2010 Page 6A-31

Gear Housing

O-ring and seal lips; outside diameter of reverse gear bearing
95 2-4-C with Teflon 92-802859A 1
and bearing carrier bore
11. Install thrust washer. Coat thrust washer with High Performance Gear Lubricant.
a a - Thrust washer
7232

87 Thrust washers 92-858064K01
Lubricant
12. Install thrust bearing. Coat thrust bearing with High Performance Gear Lubricant.
a
a - Thrust bearing
7233

87 Thrust bearing 92-858064K01
Lubricant
Page 6A-32 90-8M0047659 JULY 2010

Gear Housing
13. Apply High Performance Gear Lubricant to bearing surface of reverse gear and install reverse gear.
a
a - Reverse gear
b - Bearing surface
7234

87 Reverse gear bearing surface 92-858064K01
Lubricant
Propeller Shaft Assembly

1. Install the components into the propeller shaft in the sequence shown.
NOTE: When installing the clutch, ensure the ratcheting clutch teeth (angled) are toward forward gear, and the nonratcheting
(square on both sides) are toward reverse gear.
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
90-8M0047659 JULY 2010 Page 6A-33

Gear Housing
3. Install the clutch spring. Do not allow the spring coils to overlap each other.
a
a - Spring
7193
Driveshaft Wear Sleeve Installation

1. Install a new rubber ring and apply a light coat of Loctite 271 Threadlocker on the outside diameter.
a
a - Rubber ring
7200

7 Loctite 271 Threadlocker Outside diameter of driveshaft rubber ring 92-809819
2. Insert the sleeve into the holder.
a - Sleeve
b - Holder
a
b
7243
Page 6A-34 90-8M0047659 JULY 2010

Gear Housing
3. Press the sleeve onto the driveshaft using the wear sleeve installation tool. Continue pressing until the upper and lower part
of the tool make surface to surface contact.
a- Driveshaft
b b- Wear sleeve installation tool
c- Upper part of tool
d- Lower part of tool
a 7244
Wear Sleeve Installation Tool 9114310T 1

4. Remove excess Loctite from the assembled shaft.
Lower Driveshaft Bearing Race Installation

1. Lubricate outside diameter of bearing race with 24C with Teflon.
2. Install shims and bearing race into housing. If shims were lost or a new gear housing is used during reassembly, start with
0.635 mm (0.025 in.) shims.
NOTE: Verify shims are not displaced when drawing up race. Once shims and bearing cup are in place, position gear housing
assembly so the driveshaft is vertical. This will aid in preventing the bearing cup from becoming misaligned in the bore.
a- Shims
b- Bearing race
e c- Mandrel
d- Mandrel
e- Threaded rod
f f- Nut
d
c
7246
90-8M0047659 JULY 2010 Page 6A-35

Gear Housing

95 2-4-C with Teflon Outside diameter of bearing race 92-802859A 1
Oil Sleeve Installation

Install oil sleeve with tab positioned as shown.
b
a - Oil sleeve
b - Tab
7263
Driveshaft Upper Bearing Installation

1. Lubricate inside diameter of bearing sleeve and outside diameter of bearing with 24C with Teflon.
2. Press bearing into sleeve with a mandrel.
a- Mandrel
b- Bearing
c- Bearing sleeve
d- Tapered end
c b
7264
Bearing Installation Puller 91 14309T02

Inside diameter of bearing sleeve and outside diameter of
95 2-4-C with Teflon 92-802859A 1
upper driveshaft bearing
3. Install bearing/sleeve into housing.
IMPORTANT: Oil sleeve must be installed prior to upper driveshaft bearing installation.
Page 6A-36 90-8M0047659 JULY 2010

Gear Housing
IMPORTANT: Lower driveshaft bearing cup pilots the mandrel during installation of the upper driveshaft bearing/sleeve. Lower
bearing cup must be installed prior to installing upper bearing/sleeve.
a- Threaded rod
b- Nut
a c- Mandrel
d- Bearing/sleeve
e- Tapered end of sleeve
b f- Mandrel
d c
f
7268
Shift Shaft Assembly

1. Apply Loctite 271 Threadlocker to the outside diameter of the shift shaft seal.
2. Use a suitable mandrel to press the seal into the shift shaft bushing until the seal is seated against the shoulder.
3. Install an Oring onto the shift shaft bushing.
4. Apply 24C with Teflon on the Oring and the inside diameter of the shift shaft seal.
a - Seal
b - Oring
24900
b

7 Loctite 271 Threadlocker Outside diameter of shift shaft seal 92-809819
Inside diameter of shift shaft seal and shift shaft bushing O-
95 2-4-C with Teflon 92-802859A 1
ring
5. Install the Eclip onto the shift shaft.
90-8M0047659 JULY 2010 Page 6A-37

Gear Housing
6. Insert the shift shaft into the shift shaft bushing, as shown.
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.
a - Shift shaft assembly

b - Spline
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.
a - Screw (M6 x 25) (2)

a
7206
Page 6A-38 90-8M0047659 JULY 2010

Gear Housing

7 Loctite 271 Threadlocker Threads of the shift shaft bushing screws 92-809819

Screw (M6 x 25) 6.8 60
Pinion Gear Depth and Forward Gear Backlash

IMPORTANT: The forward gear assembly pilots the end of the pinion gauge and must be installed in the gear housing when
checking pinion gear depth. An inaccurate measurement will be obtained without the forward gear assembly installed.
NOTE: Read the entire procedure before attempting any change in shim thickness.
Pinion Gear Depth

1. Ensure the gear housing is clear of debris in the bearing carrier area.
2. Install the forward gear assembly into the gear housing.
3. Install the pinion gear tapered bearing into the gear housing.
4. Install the pinion gear and driveshaft.
5. Use the old pinion nut to secure the pinion gear to the driveshaft and tighten the pinion nut to the specified torque.
b a
a- Driveshaft
c- Lower driveshaft tapered bearing
d- Pinion gear
e- Pinion nut
f- Forward gear/bearing assembly
d
e
7271

Pinion nut 95 70
90-8M0047659 JULY 2010 Page 6A-39

Gear Housing
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
Bearing Preload Tool 9114311A04

7. Measure the distance between the top of the nut and the bottom of the bolt head.
8. Increase this distance by 25.4 mm (1 in.).
9. Rotate the driveshaft 510 revolutions. This will seat the driveshaft tapered roller bearing.
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
7 5 e- Collar retaining screw

a
6
f- Snap ring
c
c f
7277
Page 6A-40 90-8M0047659 JULY 2010

Gear Housing
Pinion Gear Locating Tool 9112349A05

11. Insert the pinion gear locating tool into the forward gear assembly. Position the correct gauging block flat number under the
pinion gear, as shown.
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.
90-8M0047659 JULY 2010 Page 6A-41

Gear Housing
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
Forward Gear Backlash

1. Insert the propeller shaft assembly into the bearing carrier assembly.
2. Obtain a 152 mm (6 in.) long by 3238 mm (11/4 in.11/2 in.) diameter piece of PVC pipe. Install the PVC pipe over the
propeller shaft and secure the pipe against the bearing carrier assembly with the tab washer and propeller nut. This holds the
reverse gear and thrust bearing tight against the bearing carrier, preventing possible bearing damage during installation.
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

95 2-4-C with Teflon Bearing carrier and the gear housing mating surfaces 92-802859A 1
5. Install the bearing carrier retaining washer onto the bearing carrier studs.
Page 6A-42 90-8M0047659 JULY 2010

Gear Housing
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
a
7175

Locknut 33.9 25
7. Install the puller jaws assembly.

8. Secure the driveshaft to prevent it from turning and tighten the puller bolt to the specified torque.
9. Ensure the gear shift is in neutral and rotate the driveshaft 510 revolutions to seat the forward gear tapered roller bearing.
Tighten the puller bolt to the specified torque.
a- Puller bolt
b- Propeller shaft
c- Bearing carrier
d- Puller jaws
c
a b
d 7286

Puller bolt 5 45
10. Install the dial indicator adapter to the gear housing.
90-8M0047659 JULY 2010 Page 6A-43

Gear Housing
11. Install the backlash indicator and dial indicator, as shown.
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
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.
Model Gear Ratio Tool Indicator Number

75/90 2.33:1 4
115/115 Pro XS/125 2.07:1 1
13. Lightly rotate the driveshaft back and forth. No movement should be noticed at the propeller shaft.
14. The dial indicator registers the amount of backlash. Ensure the forward gear backlash is within the specifications.
Forward Gear Backlash (all models)

15. If the backlash is less than the minimum specification, remove shims from in front of the forward gear bearing race. If the
backlash is more than the maximum specification, add shims in front of the forward gear bearing race.
NOTE: By adding or subtracting 0.025 mm (0.001 in.), the backlash will change approximately 0.025 mm (0.001 in.).
16. Remove the puller jaws assembly and the backlash indicator assembly.
17. Remove the bearing carrier and propeller shaft assembly.
18. Remove the pinion gear and driveshaft.
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.
Page 6A-44 90-8M0047659 JULY 2010

Gear Housing
5. Apply Loctite 271 Threadlocker to the pinion nut threads and install the pinion nut. Tighten the pinion nut to the specified
torque.
b a
a- Driveshaft
c- Lower driveshaft tapered bearing
d- Pinion gear
e- Pinion nut
f- Forward gear/bearing assembly
d
e
7271

117 Loctite 7649 Primer N Driveshaft threads and pinion nut threads 92-809824
7 Loctite 271 Threadlocker Pinion nut threads 92-809819

Pinion nut 95 70
6. Ensure the propeller shaft assembly is properly installed into the bearing carrier assembly.
7. Retain the propeller shaft with a 152 mm (6 in.) long by 3238 mm (11/4 in.11/2 in.) diameter piece of PVC pipe. Install the
PVC pipe over the propeller shaft and secure the pipe against the bearing carrier assembly with the tab washer and propeller
nut. This holds the reverse gear and thrust bearing tight against the bearing carrier, preventing possible bearing damage
during installation.
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.
90-8M0047659 JULY 2010 Page 6A-45

Gear Housing
9. 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

95 2-4-C with Teflon Bearing carrier and the gear housing mating surfaces 92-802859A 1
10. Install the bearing carrier retaining washer onto the bearing carrier studs.
IMPORTANT: If the bearing carrier retaining washers are not 2.29 mm (0.090 in.) thick, order new washers P/N 12855941.
11. Secure the bearing carrier with locknuts and tighten the locknuts to the specified torque.

a
a
7175

Locknut 33.9 25
Water Pump Assembly and Installation

1. Place water pump base upper seal on longer shoulder side of oil seal driver with seal lip away from shoulder.
Page 6A-46 90-8M0047659 JULY 2010

Gear Housing
2. Apply Loctite 271 Threadlocker on outside diameter of seal. Press seal into water pump base until tool bottoms.
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

7 Loctite 271 Threadlocker Outside diameter of water pump upper seal 92-809819
3. Place water pump base lower seal on short shoulder side of oil seal driver with seal lip toward shoulder.
5. Lubricate lip of each seal with 24C with Teflon.
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

7 Loctite 271 Threadlocker Outside diameter of lower water pump seal 92-809819
95 2-4-C with Teflon Lip of each seal 92-802859A 1
90-8M0047659 JULY 2010 Page 6A-47

Gear Housing
6. Install gasket.
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

7 Loctite 271 Threadlocker Water pump base screw threads 92-809819

Screw 6.8 60
8. Install gasket and plate.
a
a - Plate
c b - Gasket
c - Impeller sealing groove
7165
Page 6A-48 90-8M0047659 JULY 2010

Gear Housing
9. Install gasket, drive key, and impeller.
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

95 2-4-C with Teflon Inside diameter of water pump cover 92-802859A 1
7 Loctite 271 Threadlocker Water pump cover screw threads 92-809819

Water pump cover screw 6.8 60
NOTE: It is recommended that the gearcase be pressure tested for leaks for 5 minutes after reassembly and before gear
lubricant is added.
Gearcase Test Pressure

Applied air pressure 6983 kPa (1012 psi)
Length of time 5 minutes
Rubber Overmold Water Pump Plate

1. Place the water pump base upper seal onto the longer shoulder side of the oil seal driver with the seal lip away from the oil
seal driver shoulder.
90-8M0047659 JULY 2010 Page 6A-49

Gear Housing
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

7 Loctite 271 Threadlocker Outside diameter of water pump upper seal 92-809819
3. Place water pump base lower seal on short shoulder side of oil seal driver with seal lip toward shoulder.
5. Lubricate lip of each seal with 24C with Teflon.
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

7 Loctite 271 Threadlocker Outside diameter of lower water pump seal 92-809819
95 2-4-C with Teflon Lip of each seal 92-802859A 1
Page 6A-50 90-8M0047659 JULY 2010

Gear Housing
6. Install the gasket onto the gear housing.
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

7 Loctite 271 Threadlocker Water pump base screw threads 92-809819

Screw 6.8 60
90-8M0047659 JULY 2010 Page 6A-51

Gear Housing
8. Inspect the plate for damage to the rubber seal.
a b
29177
Top view Bottom view

a - Water pump cover seal
b - Rubber gasket
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
11. Lubricate inside diameter of cover with 24C with Teflon.

12. Rotate the driveshaft clockwise while pushing the impeller housing down and over the impeller until it contacts the water pump
base.
13. Apply Loctite 271 Threadlocker to the threads of the cover screws. Install the cover screws and tighten to the specified torque.
a - Screw (4)
b
b - Water tube seal
c c - Cover
7157
a

95 2-4-C with Teflon Inside diameter of water pump cover 92-802859A 1
Page 6A-52 90-8M0047659 JULY 2010

Gear Housing

7 Loctite 271 Threadlocker Water pump cover screw threads 92-809819

Water pump cover screw 8.5 75
NOTE: Before gear lubricant is added, pressure test the gearcase for five minutes to check for leaks.

Air pressure 6983 kPa (1012 psi)
Gear Housing Pressure Test

1. Remove vent plug and install pressure test gauge FT8950.
60 80100
40 120
20 140
0 160
7362
2. Pressurize housing and observe gauge for 5 minutes.

3. Rotate driveshaft, propeller shaft, and shift shaft while housing is pressurized to check for leaks.
4. If pressure drop is noted, immerse housing in water.
5. Repressurize and check for air bubbles.
6. Replace leaking seals, as necessary. Retest housing after seal replacement.

Applied air pressure 6983 kPa (1012 psi)

7. Remove tester from housing and install vent plug and sealing washer.
Gearcase Installation
1. Position outboard shift linkage into forward gear position.
F N R
7368
2. Tilt engine to full up position and engage tilt lock lever.
! WARNING
90-8M0047659 JULY 2010 Page 6A-53

Gear Housing
3. Shift gear housing into neutral position. Propeller shaft will rotate freely in either direction.
4. Install water tube seal. Apply 24C with Teflon to inside diameter of seal.
5. Apply a bead of RTV 587 Silicone Sealer to the water pump exhaust dam as shown.
NOTE: For ease of gear housing installation, install water tube seal labyrinth end onto water tube in driveshaft housing.
Tapered end of water tube seal goes onto water pump.
a a - Water tube seal

b - RTV 587 Silicone Sealer
b
7377

95 2-4-C with Teflon Water tube seal inner diameter 92-802859A 1
RTV 587 Ultra Blue
Silicone Sealer
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.

95 2-4-C with Teflon Driveshaft splines and shift shaft splines 92-802859A 1
8. Shift gear housing into forward gear position. In forward gear the gear housing will ratchet when propeller shaft is turned
clockwise. Resistance will be felt when propeller shaft is rotated counterclockwise.
NOTE: During installation of gear housing, it may be necessary to move the shift block located under cowl slightly to align
upper shift shaft splines with shift shaft coupler splines.
9. Apply Loctite 271 on threads of gear housing retaining screws.
10. Position gear housing so that the driveshaft is protruding into driveshaft housing.
11. Move gear housing up toward driveshaft housing, while aligning upper shift shaft splines with shift shaft coupler splines, water
tube with water tube seal, and crankshaft splines with driveshaft splines.
12. Install four fasteners and washers (two each side). Install locknut and washer.
Page 6A-54 90-8M0047659 JULY 2010

Gear Housing
13. Torque screws and locknut (or nuts only if applicable) to the specified torque.
a - Fasteners
b - Locknut and washer
a
b
7156

7 Loctite 271 Threadlocker Threads of gear housing retaining screws 92-809819

Screw or Nut 54 40
14. Check shift operation as follows:
Place shift lever in forward gear. Gear housing should ratchet when propeller shaft is turned clockwise. Resistance
should be felt when propeller shaft is turned counterclockwise.
Place shift lever in neutral. Propeller shaft should rotate freely in either direction.
While rotating propeller shaft, place shift lever in reverse gear. Resistance should be felt when propeller shaft is rotated
in either direction.
IMPORTANT: If shift operation is not as described above, the gear housing must be removed and the cause of the problem
corrected.
Filling Gear Housing with Lubricant

IMPORTANT: Do not use automotive gear lubricant in the gear housing. Use only High Performance Gear Lubricant.
1. Remove any gasket material from the fill and vent screws and the housing.
2. Install a new sealing washer on the fill and vent screws.
IMPORTANT: Never apply lubricant to the gear housing without first removing the vent screw, or the gear housing cannot be
filled because of trapped air. Fill the gear housing only when the housing is in a vertical position.
3. Slowly fill the housing through the fill hole until the lubricant flows out of one vent hole.
4. Reinstall this vent screw and sealing washer only and continue filling until excess starts to flow out of the second vent hole.
5. Rotate the driveshaft clockwise approximately 10 revolutions. Let the gear housing sit for at least one minute to allow any
trapped air to settle out, then top off the lubricant.
6. Replace the second vent screw and sealing washer.
7. Remove the gear lubricant tube from the fill hole and quickly install the fill/drain screw and sealing washer.
a- First vent screw

b- First vent hole
c c- Second vent hole
d- Second vent screw
b a d e- Fill/drain screw
27001 e
IMPORTANT: Do not lose more than 30 cc (1 oz) of gear lubricant while reinstalling the fill/drain screw.
90-8M0047659 JULY 2010 Page 6A-55

Gear Housing

87 Gear housing 92-858064K01
Lubricant

Vent screw 6.8 60
Trim Tab Adjustment and Replacement

IMPORTANT: The trim tab is now painted and does not aid in protecting the driveshaft housing and gear housing from galvanic
corrosion and pitting of metal surfaces. Side anodes now provide protection. Do not paint or place protective coating on the side
anodes, or corrosion protection function will be lost.
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

Trim tab retaining screw 30 22
Page 6A-56 90-8M0047659 JULY 2010

Throttle Cable and Shift Bracket
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
90-8M0047659 JULY 2010 Page 7A-1


Shift link bushings, shift shaft bushing
95 2-4-C with Teflon 92-802859A 1
Shift bracket
Page 7A-2 90-8M0047659 JULY 2010

Notes:
90-8M0047659 JULY 2010 Page 7A-3

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
Page 7A-4 90-8M0047659 JULY 2010


Torque
2 1 Retainer
3 4 Screw 11.3 100
4 1 Grommet
5 1 Grommet
6 1 Clamp (75.5 mm)
7 1 Screw
8 1 Washer
9 1 Washer
10 1 Bushing
13 1 Lockwasher
14 1 Spool washer
15 1 Cupped washer
17 1 Insert (75 HP) (90 HP)
18 1 Bracket
19 1 Screw (M6 x 16) 11.9 105
20 2 Cable
21 1 Cam
22 1 Bushing
23 1 Washer
24 1 Screw (M6 x 40) 10.7 95
25 1 Coupler
27 2 Screw 2.7 24
28 2 Conduit
29 1 Clamp (75.5 mm)
90-8M0047659 JULY 2010 Page 7A-5

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
Page 7A-6 90-8M0047659 JULY 2010


Torque
2 1 Retainer
3 4 Screw 11.3 100
4 1 Grommet
5 1 Grommet
6 1 Clamp
7 1 Screw
8 1 Spool washer
9 1 Cupped washer
10 1 Bushing
13 1 Lockwasher
14 1 Spool washer
15 1 Cupped washer
17 1 Roller
18 1 Bracket
19 3 Screw (M6 x 16) 11.9 105
20 2 Cable
21 1 Cam
22 1 Bushing
23 1 Washer
24 1 Screw (M6 x 40) 10.7 95
25 1 Coupler
27 3 Screw 2.7 24
28 1 Insert (75 HP) (90 HP)
29 1 Clamp (75.5 mm)
30 2 Conduit
90-8M0047659 JULY 2010 Page 7A-7

8
10
3
9
1
4 2
5
1327
11
12
Page 7A-8 90-8M0047659 JULY 2010


Torque
1 1 Throttle lever
2 1 Bumper
3 1 Bushing
4 1 Insert
5 1 Screw (M10 x 45) 27 20
6 1 Bracket
7 1 Screw (M6 x 35)
8 1 Nut (M6)
9 1 Cap
10 1 Screw (M6 x 16) 10.2 90
11 1 Washer
12 1 Nut (M6)
90-8M0047659 JULY 2010 Page 7A-9

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
Page 7A-10 90-8M0047659 JULY 2010

Exhaust Plate
Torque
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

95 2-4-C with Teflon Shift link bushings, shift shaft bushing 92-802859A 1
90-8M0047659 JULY 2010 Page 7A-11

Throttle Cable
Throttle Cable Removal
1. Loosen the four nuts securing the throttle cables to the throttle body bracket.

b
b - Nuts (4)
c - Throttle pulley
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
5. Remove the throttle cables from the throttle lever.

c - Throttle lever
c 27492
6. Remove the throttle cables from the throttle pulley.
Page 7A-12 90-8M0047659 JULY 2010

7. Bend the throttle cable retainer clamp slightly to remove the throttle cables from the retainer clamp.
27493

1. Install the throttle idle cable onto the rear mounting location on the throttle body bracket.
2. Adjust the 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.

body bracket
c c - Throttle body
27496

Nut (2) 7.3 65
3. Install the WOT throttle cable onto the front mounting location on the throttle body bracket.
90-8M0047659 JULY 2010 Page 7A-13

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.

bracket
27498

Nut (2) 7.3 65
5. Install the throttle idle cable and the throttle WOT cable to the throttle cam.
a - Throttle idle cable

c - Throttle cam
b
c
27507

a b
27508
Page 7A-14 90-8M0047659 JULY 2010

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.
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 - Throttle lever
c 27492

10. Pull on the throttle cable to remove the slack.
c
c - Nut
a
27511

Nut 7.3 65

90-8M0047659 JULY 2010 Page 7A-15

15. Thread the bottom nut to secure the WOT cable to the cable bracket. Tighten the bottom nut to the specified torque.

b - Nut
a 27512

Nut 7.3 65

17. Pull the throttle lever to the wideopen throttle position.
a - WOT stop
b
27514
a a - Throttle shutter arm clearance
27515

21. Install the fuel pump and secure with two screws. Tighten the screws to the specified torque.
Page 7A-16 90-8M0047659 JULY 2010

23. Secure the water sensor connector to the fuel hose with a cable tie. Do not collapse the fuel hose with the cable tie.
a c a - Nuts
b - Cable tie
c - Screws (2)
b
27489

Screws securing the fuel pump (2) 6.8 60
Shift Bracket Removal and Installation

Shift Bracket Removal
1. Remove the nut and washer securing the shift link to the shift slide.
2. Bend the locking tabs securing the two screws holding the shift bracket to the cylinder block.
3. Remove the two screws securing the shift bracket to the cylinder block.
c c a- Shift link
b
b- Shift bracket
link to shift slide
a
d
27705
Shift Bracket Installation

1. 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.

Shift bracket screws (M8 x 25) (2) 24.4 18
90-8M0047659 JULY 2010 Page 7A-17

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

95 2-4-C with Teflon Shift bracket 92-802859A 1
3. Install the bushing onto the shift link so the bushing flange is on top of the shift link.
4. Install the shift link onto the shift slide stud. Secure the shift link to the shift slide stud with a washer and locknut. Tighten the
locknut to the specified torque.
c c a- Shift link
b
b- Shift bracket
link to shift slide
a
d
27705

Nut 5.7 50.5
Page 7A-18 90-8M0047659 JULY 2010

Optimax75-115hp (1 5L)

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Manual Outline

90-8M0047659 JULY 2010

www.mercurymarine.com.au www.mercurymarine.com www.marinepower.com

IMPORTANT: Identifies information essential to the successful completion of the task.

Cleanliness and Care of Product

90-8M0047659 JULY 2010 Page 1A-1

75/90/115/115 Pro XS/125 OptiMax Master Specifications

Page 1A-2 90-8M0047659 JULY 2010

90-8M0047659 JULY 2010 Page 1A-3

Charging and Starting Specifications

Air Compressor Specifications

Page 1A-4 90-8M0047659 JULY 2010

Fuel System Specifications

Fuel System Specifications

Minimum Transom Opening

90-8M0047659 JULY 2010 Page 1A-5

Page 1A-6 90-8M0047659 JULY 2010

Gear Housing Specifications

Model 115/115 Pro XS/125 Gear Housing Specifications

90-8M0047659 JULY 2010 Page 1A-7

Power Trim Specifications

Power Trim Specifications S/N 0T8010001B417701

Propeller Information Charts

No. of Approx. Gross Boat Approx. Boat Propeller Part

Page 1A-8 90-8M0047659 JULY 2010

No. of Approx. Gross Boat Approx. Boat Propeller Part

90-8M0047659 JULY 2010 Page 1A-9

No. of Approx. Gross Boat Approx. Boat Propeller Part

No. of Approx. Gross Boat Approx. Boat Propeller Part

Page 1A-10 90-8M0047659 JULY 2010

No. of Approx. Gross Boat Approx. Boat Propeller Part

No. of Approx. Gross Boat Approx. Boat Propeller Part

90-8M0047659 JULY 2010 Page 1A-11

No. of Approx. Gross Boat Approx. Boat Propeller Part

Page 1A-12 90-8M0047659 JULY 2010

No. of Approx. Gross Boat Approx. Boat Propeller Part

No. of Approx. Boat Propeller Part

No. of Approx. Gross Boat Approx. Boat Propeller Part

90-8M0047659 JULY 2010 Page 1A-13

No. of Approx. Gross Boat Approx. Boat Propeller Part

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90-8M0047659 JULY 2010 Page 1B-1

Lubricant, Sealant, Adhesives

Flushing Device 9144357Q 2

Page 1B-2 90-8M0047659 JULY 2010

Selecting Accessories for Your Outboard

Manufacturer's Certificate Label

Inspection and Maintenance Schedule

90-8M0047659 JULY 2010 Page 1B-3

After Each Use

Every 100 Hours of Use or Once Yearly, Whichever Occurs First

Every 300 Hours of Use or Three Years

Before Periods of Storage

Flushing the Cooling System

1. These items should be serviced by an authorized dealer.

Page 1B-4 90-8M0047659 JULY 2010

Flushing the Cooling System (Design 2)

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Top Cowl Removal and Installation

Cleaning Care for Top and Bottom Cowls

Cleaning and Waxing Procedure

Flywheel Cover Removal and Installation

Page 1B-6 90-8M0047659 JULY 2010