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
Midsection
Section
5A - Clamp/Swivel Bracket and Driveshaft Housing
Table of Contents
Clamp Bracket Components (Power Tilt)...........................5A-4
Clamp Bracket Components (Manual Tilt)
......................... 5A-6
Steering Arm and Copilot Components........................... 5A-10
Driveshaft Housing Components..................................... 5A-12
Driveshaft Housing Cover Components...........................5A-14
Driveshaft Housing Covers.............................................. 5A-16
Removal....................................................................5A-16
Installation.................................................................5A-17
Front Cowl........................................................................5A-17
Removal....................................................................5A-17
Installation.................................................................5A-18
Idle Exhaust Port Cover................................................... 5A-19
Removal and Inspection........................................... 5A-19
Installation.................................................................5A-19
Powerhead/Midsection Assembly Separation..................5A-20
Remote Control Throttle and Shift Cables................ 5A-20
Removal....................................................................5A-20
Installation.................................................................5A-22
Engine Mount Replacement.............................................5A-23
Upper Mount............................................................. 5A-23
Lower Mount............................................................. 5A-23
Clamp Brackets, Swivel Bracket ‑ Power Tilt Models...... 5A-25
Clamp Brackets ‑ Power Tilt..................................... 5A-25
Steering Arm Removal..............................................5A-30
Power Tilt Removal...................................................5A-31
Swivel Bracket Removal........................................... 5A-32
Swivel Bracket Inspection.........................................5A-32
Swivel Bracket Installation........................................ 5A-33
Power Tilt Installation................................................5A-34
Steering Arm Installation...........................................5A-35
Clamp Brackets, Swivel Bracket ‑ Manual Tilt Models.....5A-37
Clamp Brackets ‑ Manual Tilt....................................5A-37
Steering Arm Removal..............................................5A-40
Swivel Bracket Removal........................................... 5A-41
Swivel Bracket Inspection.........................................5A-41
Swivel Bracket Installation........................................ 5A-43
Steering Arm Installation...........................................5A-44
Driveshaft Housing Removal........................................... 5A-46
Driveshaft Housing Installation........................................ 5A-47
Shift Operation................................................................. 5A-48
Kicker Strap (Tiller Handle Model)................................... 5A-48
Removal....................................................................5A-49
Installation.................................................................5A-49
Clamp/Swivel Bracket and Driveshaft Housing
90-8M0125265 eng NOVEMBER 2017 © 2018 Mercury Marine Page 5A-1
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