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.
51
Loctite® 222 Threadlocker Camshaft gear screw threads 92-809818
110
4-Stroke 10W-30 Outboard
Oil
Valve stems
Rocker shaft components and camshaft lobes
92-8M0078625
Special Tools
Lock‑Ring Pliers Snap‑On SRP‑4
4799
Aids in the removal of lock rings.
Valve Spring Compressor 91‑809494A1
3454
Removes and installs valve springs.
Cylinder Head Specifications
Parameter Specification
Maximum deck warp 0.1 mm (0.004 in.)
Number of valves 4
Number of valves per cylinder 2
Number of camshafts 1
Camshaft journal outside diameter
Pulley side 17.98 mm (0.708 in.)
Pulley side (service limit) 17.95 mm (0.707 in.)
Oil pump side 15.97 mm (0.629 in.)
Oil pump side (service limit) 15.95 mm (0.628 in.)
Cam lobe height
Intake 23.63 mm (0.9303 in.)
Exhaust 23.80 mm (0.9370 in.)
Intake and exhaust (service limit) 23.50 mm (0.9252 in.)
Valve clearance
Intake 0.13–0.17 mm (0.005–0.007 in.)
Exhaust 0.18–0.22 mm (0.007–0.008 in.)
Valve seat angles 30°, 45°, 60°
Valve spring free length 32.85 mm (1.293 in.)
Valve spring free length (service limit) 31.50 mm (1.240 in.)
Valve spring tilt limit 1.1 mm (0.043 in.)
Valve stem diameter
Intake 5.48 mm (0.216 in.)
Intake (service limit) 5.46 mm (0.215 in.)
Exhaust 5.46 mm (0.215 in.)
Exhaust (service limit) 5.44 mm (0.214 in.)
Cylindricity (maximum) 0.01 mm (0.0004 in.)
Cylinder Head
Page 4B-2 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017