Product Manual
Table Of Contents
- Notice to Users of This Manual
- Precautions
- Replacement Parts
- Cleanliness and Care of Product
- Copyright and Trademark Information
- Manual Outline
- Section 1A - Specifications
- Table of Contents
- Model Specifications
- Ignition Specifications at 20 °C (68 °F)
- Charging and Starting Specifications
- Fuel System Specifications
- Cylinder Block/Crankcase Specifications
- Piston Specifications
- Cylinder Head Specifications
- Oil System Specifications
- Cooling System Specifications
- Power Tilt Specifications
- Gearcase Specifications
- Section 1B - Maintenance
- Table of Contents
- Cleaning Care
- Inspection and Maintenance Schedule
- Battery Inspection
- Flushing the Cooling System
- Fuel System
- Fuse Replacement - Electric Start Models
- Spark Plug Inspection and Replacement
- Timing Belt Inspection
- Engine Oil
- Corrosion Control Anodes
- Propeller Replacement
- Gearcase Lubrication
- Lubrication Points
- Storage Preparation
- Section 1C - General Information
- Table of Contents
- Recording Serial Number
- Model Year Production Code
- Engine Component Identification - Manual Start Model
- Engine Component Identification - Electric Start Model
- Following Complete Submersion
- Fuel Requirements
- Painting Procedures
- Emissions
- Shipping of Hazardous Material (HazMat) and Engine/Components Containing Hazardous Material
- Section 1D - Outboard Installation
- Section 1E - General Troubleshooting
- Table of Contents
- Conditions Affecting Performance
- Compression Check
- Cylinder Leakage Test
- Guardian Protection System
- Warning System
- Troubleshooting without a Computer Diagnostic System (CDS)
- Troubleshooting with CDS G3
- Accessing ECM Information with CDS G3
- CDS G3 Screens (10/15/20 EFI)
- Engine Control Module Pinout
- Fault Codes
- Section 2A - Ignition
- Table of Contents
- Ignition Specifications at 20 °C (68 °F)
- Ignition Theory of Operation
- General Troubleshooting
- Engine Control Module (ECM)
- Wire Color Code Abbreviations
- Sensors
- Ignition Components
- Section 2B - Charging and Starting Systems
- Section 3A - Fuel System Operation
- Section 3B - Troubleshooting and Diagnostics
- Section 3C - Service Procedures
- Section 4A - Cylinder Block/Crankcase
- Table of Contents
- Cylinder Block/Crankcase Specifications
- Piston Specifications
- Cylinder Block and Crankcase Components
- Crankshaft Components
- Powerhead Removal
- Cylinder Block Disassembly
- Powerhead Cleaning, Inspection, and Repair
- Powerhead Assembly
- Powerhead Installation
- Section 4B - Cylinder Head
- Section 4C - Oil Pump
- Section 4D - Cooling System
- Section 5A - Clamp/Swivel Bracket and Driveshaft Housing
- Table of Contents
- Clamp Bracket Components (Power Tilt)
- Clamp Bracket Components (Manual Tilt)
- Steering Arm and Copilot Components
- Driveshaft Housing Components
- Driveshaft Housing Cover Components
- Driveshaft Housing Covers
- Front Cowl
- Idle Exhaust Port Cover
- Powerhead/Midsection Assembly Separation
- Engine Mount Replacement
- Clamp Brackets, Swivel Bracket - Power Tilt Models
- Clamp Brackets, Swivel Bracket - Manual Tilt Models
- Driveshaft Housing Removal
- Driveshaft Housing Installation
- Shift Operation
- Kicker Strap (Tiller Handle Model)
- Section 5B - Power Tilt
- Table of Contents
- Power Tilt Specifications
- General Troubleshooting
- Power Tilt - General Information
- Power Tilt Components
- Theory of Operation
- Power Tilt Features and Operation
- Check Fluid and Purge the Power Tilt System
- Cowl-Mounted Tilt Switch
- Troubleshooting the Power Tilt System
- Power Tilt Removal
- Manual Release Valve Removal and Repair
- Power Tilt Motor
- Power Tilt Pump
- Power Tilt Installation
- Section 6A - Gear Housing (2.15:1)
- Table of Contents
- Gearcase Specifications
- Gear Housing and Driveshaft
- Propeller Shaft
- General Service Recommendations
- Draining and Inspecting Gear Housing Lubricant
- Gear Housing Removal
- Gear Housing Disassembly
- Gear Housing Assembly
- Pinion Bearing Installation
- Forward Gear Bearing Installation
- Bearing Carrier Assembly
- Water Pump Base Assembly
- Propeller Shaft Assembly
- Pinion Gear and Driveshaft Installation
- Forward Gear Backlash
- Shift Shaft and Water Pump Base Installation
- Water Pump Cover Assembly
- Propeller Shaft and Bearing Carrier Installation
- Gear Housing Installation
- Propeller Installation
- Section 7A - Throttle and Shift Linkage
- Section 7B - Tiller Handle
- Section 8A - Recoil Starter
- Section 9A - Color Diagrams
Lubricant, Sealant, Adhesives
Tube Ref No. Description Where Used Part No.
Quickleen Engine & Fuel
System Cleaner
Fuel tank 8M0047931
Extreme Grease
Driveshaft splines
Propeller shaft
Swivel bracket, transom clamp screws, tilt tube, propeller shaft,
steering cable grease
8M0071842
81
Anti-Seize Compound Spark plug threads 92-898101389
95
2-4-C with PTFE
Throttle cable barrels and the shift cable rod end
Propeller shaft
Swivel bracket, transom clamp screws, tilt tube, throttle/shift
cables, steering cable grease fitting
92-802859A 1
120
Corrosion Guard External metal surfaces (except corrosion control anodes) 92-802878 55
Cleaning Care
Do Not Use Caustic Cleaning Chemicals
IMPORTANT: Do not use caustic cleaning chemicals on the outboard power package. Some cleaning products contain strong
caustic agents such as hull cleaners with hydrochloric acid. These cleaners can degrade some of the components they come in
contact with including critical steering fasteners.
Damage to steering fasteners may not be obvious during visual inspection and this damage may lead to catastrophic failure.
Some caustic cleaning chemicals may cause or accelerate corrosion. Exercise caution when using cleaning chemicals around
the engine and follow the recommendations on the packaging of the cleaning product.
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 (92‑859026K 1).
Inspection and Maintenance Schedule
Before Each Use
Refer to the Owner's Manual for a list of checks and inspections that the owner should perform before each use.
After Each Use
Refer to the Owner's Manual for a list of procedures that the owner should perform after each use.
Every 100 Hours of Use or Once Yearly, Whichever Occurs First
• Change the engine oil and replace the oil filter. The oil should be changed more often when the engine is operated under
adverse conditions, such as extended trolling. Refer to Engine Oil.
•
Check the water‑separating fuel filter for contaminants. Replace filter if required. Refer to Fuel System.
•
Remove the propeller and lubricate the propeller shaft. Refer to Propeller Replacement.
•
Check the corrosion control anodes. Check more frequently when used in saltwater. Refer to Corrosion Control Anodes.
•
Drain and replace the gearcase lubricant. Refer to Gearcase Lubrication.
•
Inspect the battery. Refer to Battery Inspection.
• Saltwater use: Remove and inspect the spark plugs for corrosion, and replace as necessary. Apply Anti‑Seize Compound
only to the threads of the spark plug prior to installation. Refer to Spark Plug Inspection and Replacement.
Maintenance
Page 1B-2 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017