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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

Important Information
1
Section 1A - Specifications A
Table of Contents
75/90/115/115 Pro XS/125 OptiMax Master Specifications MidSection Specifications..........................................1A-7
.......................................................................................1A-2 Gear Housing Specifications......................................1A-7
General Specifications................................................1A-2 Power Trim Specifications..........................................1A-8
Maintenance Specifications........................................1A-3 Cooling Specifications................................................1A-8
Ignition Specifications.................................................1A-3 Propeller Information Charts..............................................1A-8
Charging and Starting Specifications..........................1A-4 75 OptiMax.................................................................1A-8
Air Compressor Specifications....................................1A-4 90 OptiMax...............................................................1A-10
Fuel System Specifications.........................................1A-5 115 OptiMax.............................................................1A-11
Installation Specifications...........................................1A-5 115 Pro XS...............................................................1A-13
Powerhead Specifications..........................................1A-6 125 OptiMax.............................................................1A-13

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
Maintenance Specifications
Recommended fuel type Unleaded 87 octane minimum
Recommended oil TCW3 Premium Plus or OptiMax 2Cycle Outboard Oil
Oil tank capacity
Engine reservoir capacity 4.72 liter (5 US qt)
External tank (optional) 11.4 liter (12 US qt)
Spark plug type NGK PZFR6H or IZFR5J
Spark plug gap 0.8 mm (0.031 in.)
1000 marine cranking amp (minimum)
Battery rating 800 cold cranking amp (minimum)
180 amp hours (minimum)
Gearcase capacity 665.0 ml (22.5 fl oz)
Water pressure
At 625 RPM (Idle) 20.641.3 kPa (36 psi)
At 5750 RPM (WOT) 75.896.5 kPa (1114 psi)

Ignition Specifications
Ignition Specifications
Type Digital inductive
Firing order 123
Spark plug type NGK PZFR6H or IZFR5J
Spark plug gap 0.8 mm (0.031 in.)
Spark plug lead resistance at 20 C (68 F) 11701330 ohms
Maximum timing Not adjustable; controlled by PCM
Idle timing Not adjustable; controlled by PCM
Throttle position sensor
At idle 0.171.05 VDC
At wideopen throttle 3.764.64 VDC
Crankshaft position sensor
Air gap (S/N 1785000 and above) Not adjustable
Air gap (S/N 0G5900000T178499) 5 mm (0.20 in.)
Resistance at 20 C (68 F) 300350 ohms

90-8M0047659 JULY 2010 Page 1A-3


Specifications

Charging and Starting 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 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.
Normal 41.054.8 kPa (68 psi)
Minimum 27.4 kPa (4 psi)
Maximum 68.5 kPa (10 psi)

Fuel System Specifications


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
Powerhead Specifications
Number of cylinders 3
Displacement 1523.5 cc (92.9 cu. in.)
Stroke 76.2 mm (3.0 in.)
Standard cylinder bore diameter 92.1131 mm (3.6265 in.)
Cylinder bore maximum taper (service) 0.076 mm (0.003 in.)
Cylinder bore maximum out of round (service) 0.076 mm (0.003 in.)
Oversize cylinder bore diameter 0.038 mm (0.015 in.) 92.4941 mm (3.6415 in.)
Oversize cylinder bore diameter 0.076 mm (0.030 in.) 92.8751 mm (3.6565 in.)
Cylinder liner type Cast iron
Compression 620758 kPa (90110 psi) 1.
Crankshaft
Maximum runout 0.0508 mm (0.002 in.)
Main bearing journal 41.275041.2877 mm (1.62501.6255 in.)
Bottom main bearing journal 35.008835.0215 mm (1.37831.3788 in.)
Crankshaft pin journal 35.986735.9994 mm (1.41681.4173 in.)
Connecting rod wrist pin bore diameter 28.077128.0898 mm (1.10541.1059 in.)
Connecting rod crankshaft pin diameter 44.046144.0588 mm (1.73411.7346 in.)
Piston type Aluminum
Piston skirt standard diameter 91.9226 0.0127 mm (3.619 0.0005 in.)
Piston skirt oversize diameter 0.038 mm (0.015 in.) 92.3036 0.0127 mm (3.634 0.0005 in.)
Piston skirt oversize diameter 0.076 mm (0.030 in.) 92.6846 0.0127 mm (3.649 0.0005 in.)
Piston wrist pin bore diameter 23.317423.3260 mm (0.91800.9183 in.)
Piston ring end gap 0.250.46 mm (0.0100.018 in.)
Wrist pin diameter 23.309023.3166 mm (0.91760.9179 in.)
Reed stand open (maximum) 0.51 mm (0.020 in.)
Thermostat
Stamped opening temperature 143
Start to open temperature 6062.7 C (140145 F)
Full open temperature 73.8 C (165 F)
Piston height at full open temperature (minimum) 3.302 mm (0.130 in.)
Water pressure
at 625 RPM (idle) 20.641.3 kPa (36 psi)
at 5750 RPM (WOT) 75.896.5 kPa (1114 psi)
Poppet valve opening 48.362.1 kPa (79 psi)

1. When performing cylinder compression test, place lanyard switch in the "OFF" position to prevent operation of direct injectors or remove fuse
controlling fuel and direct injectors.

Page 1A-6 90-8M0047659 JULY 2010


Specifications

MidSection Specifications
MidSection Specifications
Recommended transom height:
Long shaft 51 cm (20 in.)
Extra long shaft 64 cm (25 in.)
Steering pivot range 60
Full tilt up angle 75
Trim range 20
Tilt pin adjustment positions 5
Acceptable leakdown in 24 hours 25.4 mm (1 in.)
Allowable transom thickness (minimum) 76.2 mm (3 in.)

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
Gearcase capacity 665 ml (22.5 fl oz)
Lubricant type Premium Gear Lubricant
Forward gear number of teeth 29 spiral/bevel
Pinion gear number of teeth 14 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 open1. 1800 RPM
Leak test 6983 kPa (1012 psi) for 5 minutes

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)
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)

Cooling Specifications
Cooling Specifications
Thermostat
Stamped opening temperature 143
Start to open temperature 6062.7 C (140145 F)
Full open temperature 73.8 C (165 F)
Piston height at full open temperature (minimum) 3.302 mm (0.130 in.)
Water pressure
At 625 RPM (idle) 20.641.3 kPa (36 psi)
At 5750 RPM (WOT) 75.896.5 kPa (1114 psi)
Poppet valve opening pressure 48.362.1 kPa (79 psi)
Horn activation and speed reduction is dependent on engine RPM and
Cylinder block over temperature horn activation
load
Air compressor over temperature horn activation 90 C (194 F)

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

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


Diameter Pitch Model Speed Range
Blades Wgt. Length Number
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
Aluminum (15002200 lb) (1618 ft) (3547 MPH)
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
Aluminum (18002800 lb) (1720 ft) (2942 MPH)
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
Aluminum (21003500 lb) (1921 ft) (2437 MPH)
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
Aluminum (29005200 lb) (2022 ft) (2134 MPH)
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
Aluminum (32006300 lb) (2123 ft) (1831 MPH)
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
Aluminum (35007300 lb) (2124 ft) (1629 MPH)
Black Max 1587.53311.2 kg 6.47.3 m 25.746.6 km/h
14 14 4 48899018A45
Aluminum (35007300 lb) (2124 ft) (1629 MPH)
Black Max 1814.34309.1 kg 6.79.1 m 20.941.8 km/h
14 13 3 4877340A45
Aluminum (40009500 lb) (2230 ft) (1326 MPH)
Black Max 1814.34309.1 kg 6.79.1 m 20.941.8 km/h
14 13 4 48899016A45
Aluminum (40009500 lb) (2230 ft) (1326 MPH)
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
14 11 3 2494.7 kg (5500 + lb) Pontoon/work 4877338A45
Aluminum (120 MPH)

90-8M0047659 JULY 2010 Page 1A-9


Specifications

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


Diameter Pitch Model Speed Range
Blades Wgt. Length Number
Black Max 1.632.1 km/h
14 11 4 2494.7 kg (5500 + lb) Pontoon/work 48899012A45
Aluminum (120 MPH)

90 OptiMax
Wideopen throttle RPM: 50005750
Recommended transom height: 50.8 cm (20 in.), 63.5 cm (25 in.)
Gear reduction: 2.33:1
Righthand rotation (RH): Standard

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)
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
Aluminum (15002200 lb) (1618 ft) (3547 MPH)
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
Aluminum (18002800 lb) (1720 ft) (2942 MPH)
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
Aluminum (21003500 lb) (1921 ft) (2437 MPH)
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

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


Diameter Pitch Model Speed Range
Blades Wgt. Length Number
Black Max 1315.42358.6 kg 6.096.7 m 33.754.7 km/h
13.25 16 3 48854360A45
Aluminum (29005200 lb) (2022 ft) (2134 MPH)
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
Aluminum (32006300 lb) (2123 ft) (1831 MPH)
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
Aluminum (35007300 lb) (2124 ft) (1629 MPH)
Black Max 1587.53311.2 kg 6.47.3 m 25.746.6 km/h
14 14 4 48899018A45
Aluminum (35007300 lb) (2124 ft) (1629 MPH)
Black Max 1814.34309.1 kg 6.79.1 m 20.941.8 km/h
14 13 3 4877340A45
Aluminum (40009500 lb) (2230 ft) (1326 MPH)
Black Max 1814.34309.1 kg 6.79.1 m 20.941.8 km/h
14 13 4 48899016A45
Aluminum (40009500 lb) (2230 ft) (1326 MPH)
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
14 11 3 2494.7 kg (5500 + lb) Pontoon/work 4877338A45
Aluminum (120 MPH)
Black Max 1.632.1 km/h
14 11 4 2494.7 kg (5500 + lb) Pontoon/work 48899012A45
Aluminum (120 MPH)

115 OptiMax
Wideopen throttle RPM: 50005750
Recommended transom height: 50.8 cm (20 in.), 63.5 cm (25 in.)
Gear reduction: 2.07:1
Righthand rotation (RH): Standard

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


Diameter Pitch Model Speed Range
Blades Wgt. Length Number
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
Aluminum (14001700 lb) (1517 ft) (5563 MPH)
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

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


Diameter Pitch Model Speed Range
Blades Wgt. Length Number
Black Max 771.1861.8 kg 4.55.2 m 80.491.7 km/h
12.75 21 3 4877348A45
Aluminum (17001900 lb) (1517 ft) (5057 MPH)
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
Aluminum (19002300 lb) (1618 ft) (4451 MPH)
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
Aluminum (22002700 lb) (1719 ft) (3846 MPH)
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
Aluminum (23003000 lb) (1720 ft) (3543 MPH)
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
Aluminum (26003500 lb) (1821 ft) (3140 MPH)
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
Aluminum (28004000 lb) (1923 ft) (2837 MPH)
Black Max 12701814.3 kg 5.77.0 m 4559.5 km/h
14 14 4 48899018A45
Aluminum (28004000 lb) (1923 ft) (2837 MPH)
Black Max 1496.82222.6 kg 6.097.3 m 38.653.1 km/h
14 13 3 4877340A45
Aluminum (33004900 lb) (2024 ft) (2433 MPH)
Black Max 1496.82222.6 kg 6.097.3 m 38.653.1 km/h
14 13 4 48899016A45
Aluminum (33004900 lb) (2024 ft) (2433 MPH)
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)
Black Max 27.343.4 km/h
14 11 3 1905 kg (4200 + lb) Pontoon/work 4877338A45
Aluminum (1727 MPH)
Black Max 27.343.4 km/h
14 11 4 1905 kg (4200 + lb) Pontoon/work 48899012A45
Aluminum (1727 MPH)
1.632.1 km/h
14 10 3 Vengeance 2267.9 kg (5000 + lb) Workboat 4817310A46
(120 MPH)
Black Max 1.632.1 km/h
14 10 3 2267.9 kg (5000 + lb) House/work 48854342A45
Aluminum (120 MPH)

Page 1A-12 90-8M0047659 JULY 2010


Specifications

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


Diameter Pitch Model Speed Range
Blades Wgt. Length Number
Black Max 1.632.1 km/h
14 10 4 2267.9 kg (5000 + lb) House/work 48899010A45
Aluminum (120 MPH)

115 Pro XS
Wideopen throttle RPM: 50005750
Recommended transom height: 50.8 cm (20 in.), 63.5 cm (25 in.)
Gear reduction: 2.07:1
Righthand rotation (RH): Standard

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
Wideopen throttle RPM: 50005750
Recommended transom height: 50.8 cm (20 in.), 63.5 cm (25 in.)
Gear reduction: 2.07:1
Righthand rotation (RH): Standard

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


Diameter Pitch Model Speed Range
Blades Wgt. Length Number
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

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


Diameter Pitch Model Speed Range
Blades Wgt. Length Number
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
Aluminum (22003000 lb) (1619 ft) (3849 MPH)
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
Aluminum (26003600 lb) (1719 ft) (3343 MPH)
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
Aluminum (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)
Black Max 1542.22222.6 kg 5.86.7 m 41.854.7 km/h
13.25 16 3 48854360A45
Aluminum (34004900 lb) (1922 ft) (2634 MPH)
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
Aluminum (38005500 lb) (1923 ft) (2431 MPH)
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
Aluminum (43006200 lb) (2125 ft) (2229 MPH)
Black Max 2131.83175.0 kg 6.77.9 m 32.243.5 km/h
14 13 3 4877340A45
Aluminum (47007000 lb) (2226 ft) (2027 MPH)
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

Important Information
1
Section 1B - Maintenance B
Table of Contents
Maintenance Specifications...............................................1B-2 Fuel Filter Replacement..............................................1B-8
Selecting Accessories for Your Outboard..........................1B-3 Draining Water from the Fuel Filter Chamber.............1B-8
EPA Regulations................................................................1B-3 Steering Link Rod Fasteners.............................................1B-8
Manufacturer's Certificate Label........................................1B-3 Fuse Replacement.............................................................1B-9
Family Number...........................................................1B-3 Inline Oil Filter Replacement ..........................................1B-10
Inspection and Maintenance Schedule..............................1B-3 Corrosion Control Anode.................................................1B-10
Before Each Use.........................................................1B-3 Battery Inspection ...........................................................1B-11
After Each Use............................................................1B-4 Battery Information...........................................................1B-11
Every 100 Hours of Use or Once Yearly, Whichever Propeller Replacement....................................................1B-12
Occurs First.............................................................1B-4 Spark Plug Inspection and Replacement.........................1B-14
Every 300 Hours of Use or Three Years.....................1B-4 Compressor Air Intake Filter............................................1B-14
Before Periods of Storage..........................................1B-4 Removal....................................................................1B-14
Flushing the Cooling System.............................................1B-4 Installation.................................................................1B-15
Flushing the Cooling System Models with Accessory Flush Alternator Belt Inspection.................................................1B-15
Hose Attachment............................................................1B-5 Lubrication Points............................................................1B-16
Flushing the Cooling System (Design 1)....................1B-5 Checking Power Trim Fluid..............................................1B-17
Flushing the Cooling System (Design 2)....................1B-5 Gearcase Lubrication.......................................................1B-17
Top Cowl Removal and Installation...................................1B-6 Draining Gearcase....................................................1B-18
Removal......................................................................1B-6 Gearcase Lubricant Capacity...................................1B-18
Installation...................................................................1B-6 Gearcase Lubricant Recommendation.....................1B-18
Cleaning Care for Top and Bottom Cowls.........................1B-6 Checking Lubricant Level and Filling Gearcase.......1B-18
Cleaning and Waxing Procedure................................1B-6 Submerged Outboard......................................................1B-18
Flywheel Cover Removal and Installation..........................1B-6 Storage Preparation.........................................................1B-18
Removal......................................................................1B-6 Protecting Internal Engine Components...................1B-20
Installation...................................................................1B-7 Protecting External Outboard Components..............1B-20
Side Panel Removal and Installation.................................1B-7 Gearcase..................................................................1B-20
Removal......................................................................1B-7 Draining Hose Flush Attachment (if Equipped).........1B-20
Installation...................................................................1B-7 Positioning Outboard for Storage.............................1B-20
Fuel System.......................................................................1B-7 Battery Storage.........................................................1B-20
Fuel Line Inspection....................................................1B-8

90-8M0047659 JULY 2010 Page 1B-1


Maintenance

Maintenance Specifications
Maintenance Specifications
Recommended fuel type Unleaded 87 octane minimum
Recommended oil TCW3 Premium Plus or OptiMax 2Cycle Outboard Oil
Oil tank capacity
Engine reservoir capacity 4.72 liter (5 US qt)
External tank (optional) 11.4 liter (12 US qt)
Spark plug type NGK PZFR6H or IZFR5J
Spark plug gap 0.8 mm (0.031 in.)
1000 marine cranking amp (minimum)
Battery rating 800 cold cranking amp (minimum)
180 amp hours (minimum)
Gearcase capacity 665.0 ml (22.5 fl oz)
Water pressure
At 625 RPM (Idle) 20.641.3 kPa (36 psi)
At 5750 RPM (WOT) 75.896.5 kPa (1114 psi)

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

Fuel Filter Removal/Installation Tool 91896661

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.

Description Nm lbin. lbft


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
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. 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

Tube Ref No. Description Where Used Part No.


94 Anti-Corrosion Grease Propeller shaft 92-802867Q 1
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.

Description Nm lbin. lbft


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
Spark plug gap 0.80 mm (0.030 in.)
4. Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs fingertight, and then tighten 1/4 turn or
torque to specifications.

Description Nm lbin. lbft


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

Description Nm lbin. lbft


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.

Tube Ref No. Description Where Used Part No.


94 Anti-Corrosion Grease Propeller shaft 92-802867Q 1
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.

Tube Ref No. Description Where Used Part No.


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.

Tube Ref No. Description Where Used Part No.


Power Trim and Steering
114 Power trim reservoir 92-858074K01
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).

Tube Ref No. Description Where Used Part No.


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

Important Information
1
Section 1C - General Information C
Table of Contents
Serial Number Location.....................................................1C-2 Fuel Filter Replacement...........................................1C-28
Powerhead Starboard View (S/N 1B417702 and Above) Draining Water from the Fuel Filter Chamber...........1C-28
.......................................................................................1C-4 Warning System..............................................................1C-29
Powerhead Induction Manifold View (S/N 1B417702 and Warning Horn Signals...............................................1C-29
Above)............................................................................1C-6 Engine Guardian System..........................................1C-29
Powerhead Port View (S/N 1B417702 and Above)...........1C-8 SmartCraft Product...................................................1C-29
Powerhead Aft View (S/N 1B417702 and Above)...........1C-10 Power Trim and Tilt..........................................................1C-30
Powerhead Top View (S/N 1B417702 and Above)..........1C-12 Power Trim Operation..............................................1C-30
Powerhead Front View (S/N 1B417701 and Below)........1C-14 Tilting Operation.......................................................1C-31
Powerhead Starboard View (S/N 1B417701 and Below) 1C-16 Manual Tilting...........................................................1C-31
Powerhead Port View (S/N 1B417701 and Below)..........1C-18 Shallow Water Operation..........................................1C-31
Powerhead Top View (S/N 1B417701 and Below)..........1C-20 Auxiliary Tilt Switch...................................................1C-31
Powerhead Aft View (S/N 1B417701 and Below)............1C-22 Compression Check........................................................1C-31
Conditions Affecting Performance...................................1C-23 Cylinder Leakage Testing................................................1C-32
Weather....................................................................1C-23 Analysis....................................................................1C-32
Weight Distribution (Passengers and Gear) Inside the Painting Procedures........................................................1C-32
Boat.......................................................................1C-23 Propellers.................................................................1C-32
Bottom of Boat .........................................................1C-23 Gear Housing...........................................................1C-33
Water Absorption......................................................1C-24 Shipping of Hazardous Material (HazMat) and Engine/
Cavitation..................................................................1C-24 Components Containing Hazardous Material..............1C-33
Ventilation.................................................................1C-24 Outboard Service Bulletin 200807...........................1C-33
Following Complete Submersion.....................................1C-24 Overview of Regulations...........................................1C-34
Saltwater Submersion (Special Instructions)............1C-24 Overview of Training Requirements.........................1C-34
Engine Submerged While Running (Special Shipping of Complete Engines and Major Assemblies
Instructions)..........................................................1C-24 ..............................................................................1C-34
Freshwater Submersion (Special Instructions).........1C-24 More Information on Hazardous Material.................1C-34
Fuel and Oil.....................................................................1C-25 Decal Application.............................................................1C-34
Fuel Recommendations............................................1C-25 Decal Removal.........................................................1C-34
Fuel Requirements...................................................1C-26 Application Instructions.............................................1C-34
Fuel Additives...........................................................1C-26 Trim Tab Adjustment.......................................................1C-35
Avoiding Fuel Flow Restriction.................................1C-26 Engine BreakIn Procedure.............................................1C-35
Oil Recommendation................................................1C-26 Gasoline/Oil BreakIn Mixture...................................1C-35
Filling Oil Injection System.......................................1C-27 BreakIn Procedure..................................................1C-35
Filling Fuel Tank.......................................................1C-28

90-8M0047659 JULY 2010 Page 1C-1


General Information

Special Tools
Fuel Filter Removal/Installation Tool 91896661

Aids in the removal and installation of the fuel filter cap assembly.

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

Fuel Filter Removal/Installation Tool 91896661

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.

Page 1C-28 90-8M0047659 JULY 2010


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.

90-8M0047659 JULY 2010 Page 1C-29


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


General Information

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.

90-8M0047659 JULY 2010 Page 1C-31


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


General Information

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

Important Information
1
Section 1D - Outboard Installation D
Table of Contents
Installation Specifications..................................................1D-2 Fuel Hose Connection..............................................1D-17
Lifting the Outboard...........................................................1D-2 Shift Cable Installation..............................................1D-18
Steering Cable Starboard Side Routed Cable.................1D-3 Throttle Cable Installation.........................................1D-19
Steering Link Rod Fasteners.............................................1D-4 Electrical, Fuel Hose, and Control Cables 0T801000
Drilling Outboard Mounting Holes......................................1D-4 1B226999.....................................................................1D-20
Determining Recommended Outboard Mounting Height Front Cover Assembly..............................................1D-20
.......................................................................................1D-6 Remote Wire Harness..............................................1D-20
Fastening the Outboard to the Transom............................1D-6 Battery Information...................................................1D-21
Mounting Bolts............................................................1D-6 Battery Cable Connections.......................................1D-22
Checking Boat Transom Construction........................1D-7 Fuel Hose Connection..............................................1D-22
Electrical, Fuel Hose, and Control Cables S/N 1B417702 Water Pressure Tube Connection............................1D-23
and Above......................................................................1D-8 Shift Cable Installation..............................................1D-23
Front Cowl Grommet..................................................1D-8 Throttle Cable Installation.........................................1D-24
Flush Hose Routing....................................................1D-9 Filling the Fuel System....................................................1D-25
Remote Boat Harness..............................................1D-10 Filling Oil Injection System...............................................1D-25
Battery Information...................................................1D-10 Priming the Oil Injection Pump........................................1D-26
Battery Cable Connections.......................................1D-11 Propeller Installation........................................................1D-27
SmartCraft Harness Connection...............................1D-11 Trim In Pin.......................................................................1D-28
Water Pressure Tube Connection............................1D-12 Paddle Wheel Speed Sensor Installation (if Equipped)...1D-28
Fuel Hose Connection..............................................1D-12 Parts Provided..........................................................1D-28
Shift Cable Installation..............................................1D-13 Selecting Location....................................................1D-29
Throttle Cable Installation.........................................1D-14 Transom Angle Requirements..................................1D-29
Electrical, Fuel Hose, and Control Cables S/N 1B227000 Installing Bracket......................................................1D-29
1B417701.....................................................................1D-15 Routing the Cable.....................................................1D-30
Front Cover Assembly..............................................1D-15 Installing and Removing the Paddle Wheel..............1D-30
Remote Wiring Harness...........................................1D-16 Wiring Connections..................................................1D-31
Battery Information...................................................1D-16 Template Paddle Wheel Speed Sensor.................1D-31
Battery Cable Connections.......................................1D-17

90-8M0047659 JULY 2010 Page 1D-1


Outboard Installation

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


Tube Ref No. Description Where Used Part No.
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


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

15363

Lifting Eye 91904551


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

Tube Ref No. Description Where Used Part No.


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


Outboard Installation
3. Torque nut to specification.

3727

Description Nm lbin. lbft


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

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.

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


Outboard Installation
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


Outboard Installation

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 Installation

Outboard Transom Mounting Hardware Supplied with Outboard


Part Number Part Name Description
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


Part Number Part Name Description
1067755005 Transom bolt 1/220 x 2.50 in. long (1.25 in. thread)
1067755006 Transom bolt 1/220 x 3.50 in. long (1.25 in. thread)
10814259 Transom bolt 1/220 x 4.00 in. long (2.25 in. thread)
10677551 Transom bolt 1/220 x 4.50 in. long (2.25 in. thread)
1067755003 Transom bolt 1/220 x 5.50 in. long (3.25 in. thread)
10677552 Transom bolt 1/220 x 6.50 in. long (2.75 in. thread)
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


Outboard Installation
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

Description Nm lbin. lbft


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


Outboard Installation
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


Outboard Installation

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
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.

Description Nm lbin. lbft


Hex nuts 13.5 120

IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.
Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied
per battery for wing nut replacement. Metric hex nuts are not supplied.

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

Page 1D-10 90-8M0047659 JULY 2010


Outboard Installation

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


Outboard Installation

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.

Fuel Hose Connection


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


Outboard Installation

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


Outboard Installation
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


Install cables into the remote control following the instructions provided with the remote control.
1. Position remote control into neutral.

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


Outboard Installation

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


Outboard Installation

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
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.

Description Nm lbin. lbft


Hex nuts 13.5 120

IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.
Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied
per battery for wing nut replacement. Metric hex nuts are not supplied.

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

Page 1D-16 90-8M0047659 JULY 2010


Outboard Installation

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

Fuel Hose Connection


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


Outboard Installation

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

Page 1D-18 90-8M0047659 JULY 2010


Outboard Installation
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


Install cables into the remote control following the instructions provided with the remote control.
1. Position remote control into neutral.

26838

2. Install throttle cable to the throttle arm with flat washer and locknut. Tighten locknut, then back off locknut 1/4 turn.
3. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop.
4. Place cable barrel into retainer.
5. Lock the retainer and cables in place with the cable latch.

a- Flat washer
b- Locknut
c- Barrel retainer
c d- Cable barrel
e- Cable latch

d
a b
e

15317

90-8M0047659 JULY 2010 Page 1D-19


Outboard Installation

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


Outboard Installation
3. Install the harness connection into the harness holder on the bottom cowl.

10392

Battery Information
! WARNING
Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading
to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose
connections.

Do not use deepcycle batteries. Engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah.
When connecting engine battery, hex nuts must be used to secure battery leads to battery posts. Torque nuts to specification.

Description Nm lbin. lbft


Hex nuts 13.5 120

IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.
Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied
per battery for wing nut replacement. Metric hex nuts are not supplied.

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

90-8M0047659 JULY 2010 Page 1D-21


Outboard Installation

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

Fuel Hose Connection


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


Outboard Installation

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

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

90-8M0047659 JULY 2010 Page 1D-23


Outboard Installation
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
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


Install cables into the remote control following the instructions provided with the remote control.
1. Position remote control into neutral.

26838

2. Install throttle cable to the throttle arm with flat washer and locknut. Tighten locknut, then back off locknut 1/4 turn.
3. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop.
4. Place cable barrel into retainer.

Page 1D-24 90-8M0047659 JULY 2010


Outboard Installation
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

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


Outboard Installation
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


Outboard Installation
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
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before
installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from
starting. Place a block of wood between the propeller blade and the antiventilation plate.

IMPORTANT: Propellers used on this product require the Mercury Marine FloTorq lll type hub 835257A9 or equivalent.

a- Propeller nut
b- Propeller nut retainer
c- Rear thrust hub
d- Propeller
e- Replaceable drive sleeve
f- Forward thrust hub
a b c d e f 3223

Tighten propeller nut to specified torque and bend tabs against nut.

a a - Propeller nut
b - Tabs

b
7919

Description Nm lbin. lbft


Propeller nut 75 55

90-8M0047659 JULY 2010 Page 1D-27


Outboard Installation

Trim In Pin
! WARNING
Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the
operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat
in a safe manner.

Some boats, particularly some bass boats, are built with a greater than normal transom angle, which will allow the outboard to be
trimmed further in or under. This greater trim under capability is desirable to improve acceleration, reduce the angle and time spent
in a bow high boat during planing off, and in some cases, may be necessary to plane off a boat with aft livewells, given the variety
of available propellers and height range of engine installations.
However, once on plane, the engine should be trimmed to a more intermediate position to avoid a bowdown planing condition
called plowing. Plowing can cause bow steering or oversteering and inefficiently consumes horsepower.

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


Outboard Installation

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


Outboard Installation

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


Outboard Installation

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


Outboard Installation

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

Ignition Specifications
Ignition Specifications
Type Digital inductive
Firing order 123
Spark plug type NGK PZFR6H or IZFR5J
Spark plug gap 0.8 mm (0.031 in.)
Spark plug lead resistance at 20 C (68 F) 11701330 ohms
Maximum timing Not adjustable; controlled by PCM
Idle timing Not adjustable; controlled by PCM
Throttle position sensor
At idle 0.171.05 VDC
At wideopen throttle 3.764.64 VDC
Crankshaft position sensor
Air gap (S/N 1785000 and above) Not adjustable
Air gap (S/N 0G5900000T178499) 5 mm (0.20 in.)
Resistance at 20 C (68 F) 300350 ohms

Lubricant, Sealant, Adhesives


Tube Ref No. Description Where Used Part No.
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

Electrical Components S/N 0T8010001B226999


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
Ref. No. Qty. Description Nm lbin. lbft
41 1 Starter cable
42 1 Boot (red)
43 1 Engine harness
44 1 Fuse cover
45 1 Mini fuse (5 amp tan)
46 4 Mini fuse (20 amp yellow)
47 1 Connector (8 pin)
48 1 Clip
49 1 Battery cable
50 1 Boot
51 3 Bushing
52 3 Washer
53 3 Screw (M8 x 35) 27 20
54 3 Grommet
55 1 Cover
56 3 Grommet
57 1 Cable
58 1 Spacer
59 1 Bracket
60 1 Tfitting
61 1 Tubing
62 1 Tubing
63 1 Coupler
64 1 Plug

Tube Ref No. Description Where Used Part No.


25 Liquid Neoprene Eyelet wiring terminals 92- 25711 3

Page 2A-6 90-8M0047659 JULY 2010


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

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
Ref. No. Qty. Description Nm lbin. lbft
1 1 Electrical plate
2 5 Screw (M6 x 14) 6.8 60
3 5 Washer
4 1 Cable assembly (braided)
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
Ref. No. Qty. Description Nm lbin. lbft
1 1 Electrical plate
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
Ref. No. Qty. Description Nm lbin. lbft
1 1 Electrical plate
2 5 Screw (M6 x 14) 6.8 60
3 5 Washer
4 1 Cable assembly (braided)
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

Throttle Body Components S/N 1B417702 and Above


Torque
Ref. No. Qty. Description Nm lbin. lbft
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

Throttle Body Components S/N 1B417701 and Below


Torque
Ref. No. Qty. Description Nm lbin. lbft
1 1 Throttle body assembly
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
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 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
26 1 Throttle position sensor
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.

Tube Ref No. Description Where Used Part No.


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.

Computer Diagnostic System (CDS) Order through SPX


Extension Cable 84825003A1

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.

90-8M0047659 JULY 2010 Page 2A-19


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

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

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.

Computer Diagnostic System (CDS) Order through SPX

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.

Page 2A-22 90-8M0047659 JULY 2010


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.

Computer Diagnostic System (CDS) Order through SPX

1. Install the grommets onto the PCM.

90-8M0047659 JULY 2010 Page 2A-23


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

Description Nm lbin. lbft


Screw (3) 4 35

4. Secure the fuse holder to the PCM with a screw. Tighten the screw to the specified torque.

Description Nm lbin. lbft


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

Page 2A-24 90-8M0047659 JULY 2010


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

Serial number 1B417702 and above

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).

Computer Diagnostic System (CDS) Order through SPX


Adapter Harness 84822560A13
Extension Cable 84825003A1

Use the DMT 2004 digital multimeter for all of the following tests.

DMT 2004 Digital Multimeter 91892647A01

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.

90-8M0047659 JULY 2010 Page 2A-25


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
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. 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.

Page 2A-30 90-8M0047659 JULY 2010


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


Flywheel Holding Tool 9152344

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 Holding Tool 9152344

Description Nm lbin. lbft


Flywheel nut 163 120
5. Install the accessory drive belt.

90-8M0047659 JULY 2010 Page 2A-31


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.

DMT 2004 Digital Multimeter 91892647A01

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


Meter Scale Reading ()
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

Description Nm lbin. lbft


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

DMT 2004 Digital Multimeter 91892647A01

Crankshaft Position Sensor


Resistance at 20 C (68 F) 300350 ohms

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.

a - Engine harness connector


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

26822

Description Nm lbin. lbft


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.

Tube Ref No. Description Where Used Part No.


7 Loctite 271 Threadlocker TPS screws 92-809819
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

Description Nm lbin. lbft


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.

Tube Ref No. Description Where Used Part No.


7 Loctite 271 Threadlocker TPS screws 92-809819
3. Install the TPS to the throttle lever bracket and secure with three screws. Tighten the screws to the specified torque.

Description Nm lbin. lbft


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.

Computer Diagnostic System (CDS) Order through SPX


Adapter Harness 84822560A13
Extension Cable 84825003A1
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

DMT 2004 Digital Multimeter 91892647A01

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.

a - Cylinder number one spark plug


b b - Cylinder block coolant temperature sensor

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.

a - Cylinder number one spark plug


b b - Cylinder block coolant temperature sensor

26966

Description Nm lbin. lbft


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.

Computer Diagnostic System (CDS) Order through SPX


Adapter Harness 84822560A13
Extension Cable 84825003A1
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

DMT 2004 Digital Multimeter 91892647A01

90-8M0047659 JULY 2010 Page 2A-45


Ignition

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 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 - Engine harness connector


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

Tube Ref No. Description Where Used Part No.


Loctite 567 PST Pipe
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 - Engine harness connector


a b b - Air compressor head temperature sensor

26976

Description Nm lbin. lbft


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.

Computer Diagnostic System (CDS) Order through SPX


Adapter Harness 84822560A13
Extension Cable 84825003A1
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

DMT 2004 Digital Multimeter 91892647A01

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.

a a - Engine harness connector


b b - Retaining bracket
c - Screw

26979

Description Nm lbin. lbft


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.

Computer Diagnostic System (CDS) Order through SPX


Adapter Harness 84822560A13
Extension Cable 84825003A1
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

DMT 2004 Digital Multimeter 91892647A01

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
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.

a - Engine harness connector


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.

a - Engine harness connector


b - Manifold air temperature sensor

a b

26985

Description Nm lbin. lbft


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
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.

Page 2A-52 90-8M0047659 JULY 2010


Ignition

Warning Horn
Function Sound Description
Engine overspeed Continuous The warning horn is activated any time engine speed exceeds the maximum
allowable RPM. The system will limit the engine speed to within the allowable range.
Engine overspeed indicates a condition that should be corrected. Overspeed could
be caused by incorrect propeller pitch, engine height, trim angle, etc.
Sensor out of range Continuous Engine Guardian System is activated. Power limit may activate at full throttle speed.
Intermittent beep Engine Guardian System is activated. Power limit may restrict engine speed to idle.
Engine running cold One beep Engine is not reaching correct temperature while operating below 1000 RPM. Have
at slow speed your dealer check the engine.

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


Charging and Starting System

Charging and Starting 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

Lubricant, Sealant, Adhesives


Tube Ref No. Description Where Used Part No.
7 Loctite 271 Threadlocker Alternator mounting screw threads 92-809819
Alternator ground screw and ring terminal
Starter brush wire terminals
25 Liquid Neoprene 92- 25711 3
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
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

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


Charging and Starting System

Notes:

90-8M0047659 JULY 2010 Page 2B-3


Charging and Starting System

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


Charging and Starting System

Flywheel/Alternator
Torque
Ref. No. Qty. Description Nm lbin. lbft
1 1 Flywheel
2 1 Damper
3 3 Screw 33.9 25
4 1 Belt
5 1 Alternator
6 2 Screw (M10 x 45) 47.5 35
7 1 Washer
8 1 Cable
9 1 Nut (M6) 5.6 50
10 1 Alternator bracket
11 1 Pin 5.1 45
12 3 Mount
13 3 Screw (M10 x 45) 47.5 35
14 6 Washer
15 1 Plug
16 1 Washer
17 1 Nut 163 120

90-8M0047659 JULY 2010 Page 2B-5


Charging and Starting System

Starter Motor Components


2

6
5

9
8 3

11 1
10

12
7

13 1339

Page 2B-6 90-8M0047659 JULY 2010


Charging and Starting System

Starter Motor Components


Torque
Ref. No. Qty. Description Nm lbin. lbft
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


Charging and Starting System

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


Charging and Starting System

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


Charging and Starting System

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


Charging and Starting System

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.

Tube Ref No. Description Where Used Part No.


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
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

90-8M0047659 JULY 2010 Page 2B-11


Charging and Starting System

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


Charging and Starting System
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


Charging and Starting System

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


Charging and Starting System

5. When installing the battery, be sure to connect the negative () (grounded) battery cable to the negative () battery terminal,
and the positive (+) battery cable to the positive (+) battery terminal. Connecting the battery cables to the battery in reverse
will result in blowing the 100 amp fusible link in the output lead of the alternator.
6. When using a charger or booster battery, connect it in parallel with the existing battery (positive to positive; negative to
negative).

Alternator Description
The alternator employs a rotor that is supported in two end frames by ball bearings, and is driven at 2.8 times engine speed. The
rotor contains a field winding enclosed between two multiplefinger pole pieces. The ends of the field winding are connected to
two brushes which make continuous sliding contact with the slip rings. The current (flowing through the field winding) creates a
magnetic field that causes the adjacent fingers of the pole pieces to become alternate north and south magnetic poles.
The 3phase stator is mounted directly over the rotor pole pieces and between the two end frames. It consists of three windings
wound 120 degrees electrically out of phase on the inside of a laminated core.
The rectifier bridge contains six diodes which allows current to flow from the ground, through the stator, and to the output terminal,
but not in the opposite direction.
When current is supplied to the rotor field winding and the rotor is turned, the movement of the magnetic fields created induces
an alternating current into the stator windings. The rectifier bridge changes this alternating current to direct current which appears
at the output terminal. The diode trio is connected to the stator windings to supply current to the regulator and the rotor field during
operation.
Voltage output of the alternator is controlled by a transistorized voltage regulator that senses the voltage at the battery, and
regulates the field current to maintain alternator voltage for properly charging the battery. Current output of the alternator does
not require regulation, as maximum current output is selflimited by the design of the alternator. As long as the voltage is regulated
within the prescribed limits, the alternator cannot produce excessive current. A cutout relay in the voltage regulator also is not
required, as the rectifier diodes prevent the battery from discharging back through the stator.
A small amount of current is supplied by the excitation circuit in the regulator to the rotor field to initially start the alternator charging.
Once the alternator begins to produce output, field current is supplied solely by the diode trio.
The alternator is equipped with two fans which induce air flow through the alternator to remove heat created by the rectifier and
stator.

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

Description Nm lbin. lbft


Locknut 5.6 50

90-8M0047659 JULY 2010 Page 2B-15


Charging and Starting System
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.

DMT 2004 Digital Multimeter 91892647A01

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


Charging and Starting System

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


b - Alternator ground

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


Charging and Starting System

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


b - Alternator ground

a b

29700

Alternator Removal
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death
due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery
before maintaining, servicing, installing, or removing engine or drive components.

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


Charging and Starting System
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

Tube Ref No. Description Where Used Part No.


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

Description Nm lbin. lbft


Screw (M10 x 50) (2) 47.5 35

90-8M0047659 JULY 2010 Page 2B-19


Charging and Starting System
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

Description Nm lbin. lbft


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


Charging and Starting System

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.

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

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.

DMT 2004 Digital Multimeter 91892647A01

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
Charging and Starting System

9 e
1 2

BLK
BLK
YEL/RED
RED
BLK

BLK
RED

RED
PUR

RED
RED
YEL/RED
BLK/YEL
PUR/WHT

C14

BLK
YEL/RED

YEL/RED

RED

BLK
S105

RED
11
Starter Circuit Troubleshooting S/N 1B417702 and Above

T9
C10

S104
g RED/BLU
RED

YEL/RED
PUR
BLK/YEL

BLK

BLK BLK

S3 S4 S2
S14
S6
RED/BLU

S1

LT BLU/WHT
BLK

LT GRN/WHT
YEL/RED

C1
PUR
RED

YEL/RED E P E P
BLK/YEL

TAN/LT BLU F D N D N
BRN

F PUR
C C
GRY G M G M
A B A
L
B
BLK/YEL H H L
J K J K
BLK
DK BLU

90-8M0047659 JULY 2010


WHT 29916
T16
BRN/WHT
Charging and Starting System

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


reading less than test point 2:
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.
Ensure the cable connection is not corroded.

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


Charging and Starting System

Starter Motor Does Not Turn


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.

No battery voltage indicated Proceed to Test 7.


Battery voltage indicated:
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)


Test Number Procedure Test Results
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


Charging and Starting System

Starter Will Not Stay Engaged (Chatter)


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
Charging and Starting System

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
Charging and Starting System

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

Starter Motor Does Not Turn


Test Number Procedure Test Results
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.
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.
(start solenoid) and a common powerhead ground. Ensure the battery cable connections are tight on the
Test 1 battery and on the powerhead.
Ensure the battery cables are not corroded.

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
(starter solenoid) and a common powerhead ground. points 1and 2.
Ensure the cable connection is not corroded.

Disconnect the lowpressure and highpressure electric fuel pumps from the engine harness. This will prevent the fuel pumps from
activation. Disconnect the crankshaft position sensor from the powerhead wire harness. This will prevent the engine from starting.
NOTE: The disconnection of the harnesses will store failure codes in the PCM. The failure codes must be erased after completing
the troubleshooting procedure.
Battery voltage is indicated and the starter solenoid clicks.
Check the battery voltage at test point 8.
Check for battery voltage at test point 3, between the Battery voltage is greater than 9.5 volts The starter
start solenoid yellow/red wire terminal and a common motor is defective.
Test 2
powerhead ground. Turn the key switch to the Battery voltage is less than 9.5 volts The starter
"START" position. solenoid is defective.

No battery voltage indicated Proceed to Test 3.


Disconnect the battery voltage supply cable at the starter solenoid test point 2. This will prevent the starter motor from cranking the
powerhead.
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 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.

Continuity indicated Proceed to Test 4.

90-8M0047659 JULY 2010 Page 2B-27


Charging and Starting System

Starter Motor Does Not Turn


Battery voltage indicated:
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:
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 7, 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 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.

No battery voltage indicated Proceed to Test 7.


Battery voltage indicated:
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.

Starter Will Not Stay Engaged (Chatter)


Test Number Procedure Test Results
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 3. 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.

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 8. Measure the resistance between the exciter Ensure battery is fully charged.
Test 2
terminal of the starter solenoid and the starter solenoid brush
lead terminal. Starter solenoid pullin coil resistance is in excess
of 0.3 10%.
Starter solenoid pullin coil is defective.

Page 2B-28 90-8M0047659 JULY 2010


Charging and Starting System

Notes:

90-8M0047659 JULY 2010 Page 2B-29


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

4
Charging and Starting System

7 8
A
B

PUR
E

1 T2
TAN/BLU
C

YEL/RED
D

C12
T7
RED
BLK
BLK

PUR
PUR
YEL/RED

RED
YEL/BLK

BLK/YEL
BLK/YEL

RED
YEL/RED

RED

BLK
RED
RED

BLK
RED

RED
10

BLK
BLK

RED
BLK

RED/PUR
PUR
GRY

YEL/RED
Starter Circuit Troubleshooting S/N 0T8010001B226999

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


Charging and Starting System

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

Starter Motor Does Not Turn


Test Number Procedure Test Results
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.
Voltage reading should be the same as the battery. Voltage
reading less than 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.
Ensure the battery cables are not corroded.

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
(starter solenoid) and a common powerhead ground. points 1and 2.
Ensure the cable connection is not corroded.

Disconnect the lowpressure and highpressure electric fuel pumps from the engine harness. This will prevent the fuel pumps from
activation. Disconnect the crankshaft position sensor from the powerhead wire harness. This will prevent the engine from starting.
NOTE: The disconnection of the harnesses will store failure codes in the PCM. The failure codes must be erased after completing
the troubleshooting procedure.
Battery voltage is indicated and the starter solenoid clicks.
Check the battery voltage at test point 8.
Check for battery voltage at test point 3, between the Battery voltage is greater than 9.5 volts The starter
start solenoid yellow/red wire terminal and a common motor is defective.
Test 2
powerhead ground. Turn the key switch to the Battery voltage is less than 9.5 volts The starter
"START" position. solenoid is defective.

No battery voltage indicated Proceed to Test 3.


Disconnect the battery voltage supply cable at the starter solenoid test point 2. This will prevent the starter motor from cranking the
powerhead.
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 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.

Continuity indicated Proceed to Test 4.

90-8M0047659 JULY 2010 Page 2B-31


Charging and Starting System

Starter Motor Does Not Turn


Battery voltage indicated:
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:
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 7, 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 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.

No battery voltage indicated Proceed to Test 7.


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.

Starter Will Not Stay Engaged (Chatter)


Test Number Procedure Test Results
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 3. 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.

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 8. Measure the resistance between the exciter Ensure battery is fully charged.
Test 2
terminal of the starter solenoid and the starter solenoid brush
lead terminal. Starter solenoid pullin coil resistance is in excess
of 0.3 10%.
Starter solenoid pullin coil is defective.

Page 2B-32 90-8M0047659 JULY 2010


Charging and Starting System

Starter Removal
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death
due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery
before maintaining, servicing, installing, or removing engine or drive components.

1. Disconnect the battery cables from the battery.


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


Charging and Starting System
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

Tube Ref No. Description Where Used Part No.


95 2-4-C with Teflon Starter solenoid plunger 92-802859A 1

Page 2B-34 90-8M0047659 JULY 2010


Charging and Starting System

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

Description Nm lbin. lbft


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

Description Nm lbin. lbft


Brush wire nut 6 55

Tube Ref No. Description Where Used Part No.


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


Charging and Starting System

Description Nm lbin. lbft


Screw 9 80

Tube Ref No. Description Where Used Part No.


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


Charging and Starting System

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


Charging and Starting System
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

Description Nm lbin. lbft


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

Tube Ref No. Description Where Used Part No.


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


Charging and Starting System

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


Charging and Starting System

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


Timing, Synchronizing, and Adjusting

Ignition Specifications
Ignition Specifications
Type Digital inductive
Firing order 123
Spark plug type NGK PZFR6H or IZFR5J
Spark plug gap 0.8 mm (0.031 in.)
Spark plug lead resistance at 20 C (68 F) 11701330 ohms
Maximum timing Not adjustable; controlled by PCM
Idle timing Not adjustable; controlled by PCM
Throttle position sensor
At idle 0.171.05 VDC
At wideopen throttle 3.764.64 VDC
Crankshaft position sensor
Air gap (S/N 1785000 and above) Not adjustable
Air gap (S/N 0G5900000T178499) 5 mm (0.20 in.)
Resistance at 20 C (68 F) 300350 ohms

Special Tools
Computer Diagnostic System (CDS) Order through SPX
Monitors all electrical systems for proper function, diagnostics, and calibration
purposes. For additional information, pricing, or to order the Computer Diagnostic
System contact:
SPX Corporation
28635 Mound Rd.
Warren, MI 48092
or call:
USA 18003452233
4520 Canada 8003452233
Europe 49 6182 959 149
Australia (03) 95446222

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).

Computer Diagnostic System (CDS) Order through SPX

Page 2C-2 90-8M0047659 JULY 2010


Timing, Synchronizing, and Adjusting

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

Description Nm lbin. lbft


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

Description Nm lbin. lbft


Nut (2) 7.3 65

90-8M0047659 JULY 2010 Page 2C-3


Timing, Synchronizing, and Adjusting

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
b - Throttle idle cable
c - Nut

a
27511

Description Nm lbin. lbft


Nut 7.3 65

10. Pull on the throttle WOT cable to remove the slack.


11. Thread the top nut so it touches the cable bracket.
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

Description Nm lbin. lbft


Nut 7.3 65

13. Loosen the WOT stop adjustment screw.

Page 2C-4 90-8M0047659 JULY 2010


Timing, Synchronizing, and Adjusting

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


Timing, Synchronizing, and Adjusting

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.)

Description Nm lbin. lbft


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


Timing, Synchronizing, and Adjusting

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


Timing, Synchronizing, and Adjusting

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


Timing, Synchronizing, and Adjusting

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


Timing, Synchronizing, and Adjusting

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 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.
Normal 41.054.8 kPa (68 psi)
Minimum 27.4 kPa (4 psi)
Maximum 68.5 kPa (10 psi)

Fuel System Specifications


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

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.

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)

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

Description Nm lbin. lbft


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

Description Nm lbin. lbft


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


Fuel Injection System

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.
Normal 41.054.8 kPa (68 psi)
Minimum 27.4 kPa (4 psi)
Maximum 68.5 kPa (10 psi)

Fuel System Specifications


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

Air Compressor Specifications


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. 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)

Page 3B-2 90-8M0047659 JULY 2010


Fuel Injection System

Lubricants, Sealants, Adhesives


Tube Ref No. Description Where Used Part No.
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


Fuel Injection System

Dual Fuel/Air Pressure Gauge Kit 91881834A 1

Tests fuel and air pressure; the dual gauges allow the viewing of both pressures
simultaneously.

5822

Fuel Filter Removal/Installation Tool 91896661

Aids in the removal and installation of the fuel filter cap assembly.

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

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

Direct Injector Removal Tool 91883521

Aids in the removal of direct injectors from the fuel rail.

8290

Page 3B-4 90-8M0047659 JULY 2010


Fuel Injection System

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


Fuel Injection System

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 3B-6 90-8M0047659 JULY 2010


Fuel Injection System

Throttle Body Components S/N 1B417702 and Above


Torque
Ref. No. Qty. Description Nm lbin. lbft
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 3B-7


Fuel Injection System

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 3B-8 90-8M0047659 JULY 2010


Fuel Injection System

Throttle Body Components S/N 1B417701 and Below


Torque
Ref. No. Qty. Description Nm lbin. lbft
1 1 Throttle body assembly
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
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 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
26 1 Throttle position sensor
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


Fuel Injection System

Air Hoses

5
6

1679

Page 3B-10 90-8M0047659 JULY 2010


Fuel Injection System

Air Hoses
Torque
Ref. No. Qty. Description Nm lbin. lbft
1 1 Hose
2 2 Clamp (15.3 mm)
3 1 Hose
4 1 Hose assembly
5 2 Cable tie
6 1 Air muffler
7 1 Hose

90-8M0047659 JULY 2010 Page 3B-11


Fuel Injection System

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


Fuel Injection System

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


Fuel Injection System

Tube Ref No. Description Where Used Part No.


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


Fuel Injection System

Notes:

90-8M0047659 JULY 2010 Page 3B-15


Fuel Injection System

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


Fuel Injection System

Vapor Separator Components S/N 1B417702 and Above


Torque
Ref. No. Qty. Description Nm lbin. lbft
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


Fuel Injection System

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


Fuel Injection System

Vapor Separator Components S/N 1B417701 and Below


Torque
Ref. No. Qty. Description Nm lbin. lbft
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
28 2 Drain screw 1.7 15
29 2 Oring
30 1 Water sensor
31 1 Fitting
32 2 Oring
33 1 Insert

90-8M0047659 JULY 2010 Page 3B-19


Fuel Injection System

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


Fuel Injection System

Reed Block Components


Torque
Ref. No. Qty. Description Nm lbin. lbft
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

Tube Ref No. Description Where Used Part No.


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 Injection System

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 Injection System

Fuel System Hoses


Torque
Ref. No. Qty. Description Nm lbin. lbft
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 Injection System

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 Injection System

Fuel Rail Components


Torque
Ref. No. Qty. Description Nm lbin. lbft
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


Fuel Injection System

Vapor Separator/Fuel Rail Mounting

10
6 3
7
9 4

110

2
6
8 7

1677

Page 3B-26 90-8M0047659 JULY 2010


Fuel Injection System

Vapor Separator/Fuel Rail Mounting


Torque
Ref. No. Qty. Description Nm lbin. lbft
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

Tube Ref No. Description Where Used Part No.


4-Stroke 10W-30 Outboard
110 Air injector seals and cupped washer 92-858045K01
Oil

90-8M0047659 JULY 2010 Page 3B-27


Fuel Injection System

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


Fuel Injection System

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

Digital Pressure Meter 91892651A01


Dual Fuel/Air Pressure Gauge Kit 91881834A 1

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


Fuel Injection System
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)

Digital Pressure Meter 91892651A01


Dual Fuel/Air Pressure Gauge Kit 91881834A 1

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


Fuel Injection System
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

Digital Pressure Meter 91892651A01


Dual Fuel/Air Pressure Gauge Kit 91881834A 1
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


Fuel Injection System
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


Fuel Injection System
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


Fuel Injection System
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

Fuel Filter Removal/Installation Tool 91896661


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


Fuel Injection System
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 Injection System

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


Fuel Injection System
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

Tube Ref No. Description Where Used Part No.


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


Fuel Injection System
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

Description Nm lbin. lbft


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

Tube Ref No. Description Where Used Part No.


36 P80 Rubber Lubricant Water sensor O-ring Obtain Locally

Description Nm lbin. lbft


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

Tube Ref No. Description Where Used Part No.


2-Cycle Premium
14 Fuel pump elbow O-rings 92-858021K01
Outboard Oil

Page 3B-38 90-8M0047659 JULY 2010


Fuel Injection System
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

Description Nm lbin. lbft


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

Description Nm lbin. lbft


Screw 1 10
12. Install the cover seal onto the VST.

27141

90-8M0047659 JULY 2010 Page 3B-39


Fuel Injection System
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

Description Nm lbin. lbft


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

Tube Ref No. Description Where Used Part No.


95 2-4-C with Teflon Fuel/water separator filter O-rings 92-802859A 1

Fuel Filter Removal/Installation Tool 91896661

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.

Hose Clamp Tool Kit 91803146A04

Page 3B-40 90-8M0047659 JULY 2010


Fuel Injection System
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

Description Nm lbin. lbft


Screw (M8 x 60) 24.4 18
Screw (M6 x 12) 10.2 90

90-8M0047659 JULY 2010 Page 3B-41


Fuel Injection System
8. Connect the engine harness connector to the electric fuel pump harness connector.

a - 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 Injection System

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 Injection System

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


Fuel Injection System

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


Fuel Injection System
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
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.

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

Page 3B-46 90-8M0047659 JULY 2010


Fuel Injection System
2. Drain the VST 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

Digital Pressure Meter 91892651A01


Dual Fuel/Air Pressure Gauge Kit 91881834A 1
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


Fuel Injection System
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


Fuel Injection System
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


Fuel Injection System
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


Fuel Injection System

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

Air Regulator Installation Tool 91889431


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


Fuel Injection System
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


Fuel Injection System
NOTE: The fuel injector ohm test is not polarity sensitive.

a - Fuel injector

ON
O FF

8309

Meter Test Leads


Meter Scale Reading ()
Red Black
Injector pin Injector pin Auto 1.8 0.1
Injector pin Injector steel body Auto No continuity

DMT 2004 Digital Multimeter 91892647A01

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


Fuel Injection System
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

Leakage Tester Kit FT8950

Direct Injector Ohm Test


Use the DMT 2004 digital multimeter to complete the following tests.

Page 3B-54 90-8M0047659 JULY 2010


Fuel Injection System

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


Meter Scale Reading ()
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

DMT 2004 Digital Multimeter 91892647A01

Meter Test Leads


Meter Scale Reading ()
Red Black
Injector pin Metal case Auto 1000 or greater

90-8M0047659 JULY 2010 Page 3B-55


Fuel Injection System

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

Description Nm lbin. lbft


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


Fuel Injection System

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

Dial Indicator 9158222A1

Description Nm lbin. lbft


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


Fuel Injection System

3. Install the cover onto the spring.


4. Install the air regulator installation tool.

a
a - Air regulator installation tool

10223

Air Regulator Installation Tool 91889431


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

Tube Ref No. Description Where Used Part No.


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.

Description Nm lbin. lbft


Screw (4) 8 70

Page 3B-58 90-8M0047659 JULY 2010


Fuel Injection System

Fuel Pressure Regulator Installation


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

Tube Ref No. Description Where Used Part No.


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

Air Regulator Installation Tool 91889431

90-8M0047659 JULY 2010 Page 3B-59


Fuel Injection System
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

Description Nm lbin. lbft


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


Fuel Injection System
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

Tube Ref No. Description Where Used Part No.


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

Description Nm lbin. lbft


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

Seal/Teflon Ring Installation Tool 918519803


Seal/Teflon Ring Sizing Tool 918519802

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.

Tube Ref No. Description Where Used Part No.


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


Fuel Injection System
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
d- Fuel hose retainer screws
e- Water outlet hose
f- Air hose retainer screws
g- Air outlet hose
h- Fuel return hose

Description Nm lbin. lbft


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


Fuel Injection System
9. Connect the engine harness connectors to the direct injectors.

a - Direct injector harness connector


b - Nuts

a b

10273

Description Nm lbin. lbft


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


Fuel Injection System

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


Fuel Injection System

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).

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

Digital Pressure Meter 91892651A01


Dual Fuel/Air Pressure Gauge Kit 91881834A 1
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


Fuel Injection System

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


Fuel Injection System
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


Fuel Injection System
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


Fuel Injection System

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


Fuel Injection System
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

Tube Ref No. Description Where Used Part No.


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

Description Nm lbin. lbft


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


Fuel Injection System
4. Insert the tensioner screw through the bushings.

a - Tensioner screw
b - Bushing (2)
c c - Belt tensioner

a b b

27356

Tube Ref No. Description Where Used Part No.


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

Tube Ref No. Description Where Used Part No.


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

Tube Ref No. Description Where Used Part No.


7 Loctite 271 Threadlocker Tensioner retaining screw threads 92-809819

90-8M0047659 JULY 2010 Page 3B-71


Fuel Injection System

Description Nm lbin. lbft


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

Tube Ref No. Description Where Used Part No.


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

Tube Ref No. Description Where Used Part No.


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


Fuel Injection System
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

Description Nm lbin. lbft


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


Fuel Injection System

Tube Ref No. Description Where Used Part No.


7 Loctite 271 Threadlocker Pin threads 92-809819
Loctite 567 PST Pipe
9 Air compressor elbow threads, inlet fitting threads 92-809822
Sealant

Description Nm lbin. lbft


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

Tube Ref No. Description Where Used Part No.


Loctite 567 PST Pipe
9 Threads of the oil return line check valves 92-809822
Sealant

Description Nm lbin. lbft


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


Fuel Injection System
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

Description Nm lbin. lbft


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

Tube Ref No. Description Where Used Part No.


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

Description Nm lbin. lbft


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

Tube Ref No. Description Where Used Part No.


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


Fuel Injection System
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

Tube Ref No. Description Where Used Part No.


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

Description Nm lbin. lbft


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