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
Step Test Procedure Test Result
Step 1: Check for
battery voltage at
point 1.
1. Connect voltmeter red lead to point 1
and black lead to ground.
2.
Press the down tilt button.
Battery voltage measured:
• Go to step 2.
No battery voltage measured:
• Go to step 3.
Step 2: Check for
battery voltage at
point 3.
Connect voltmeter red lead to point 3 and
black lead to ground.
Battery voltage measured:
• Go to step 5.
No battery voltage measured:
• There is an open circuit between point 3 and positive
(+) battery terminal.
• Check for loose or corroded connections.
• Check wires for open.
Step 3: Check for
battery voltage at
point 4.
1. Connect voltmeter red lead to point 4
and black lead to ground.
2. Press the down tilt button.
Battery voltage measured:
• Wire is open between points 4 and 1.
No battery voltage measured:
• Go to step 4.
Step 4: Check for
battery voltage at
point 5.
Connect voltmeter red lead to point 5 and
black lead to ground.
Battery voltage measured:
• Tilt switch is faulty.
No battery voltage measured:
• Check for loose or corroded wire at point 5.
• Open circuit in wire supplying current to point 5.
Step 5: Check for
battery voltage at
point 2.
1. Connect voltmeter red lead to point 2
and black lead to ground.
2. Press the down tilt button.
Battery voltage measured:
• Go to step 6.
No battery voltage measured:
• Relay is defective.
Step 6: Check up
relay.
Test up relay. Refer to Power Tilt Relay
Test, preceding.
Relay is good:
• Pump motor wiring is defective.
• Pump motor is defective.
Relay is faulty:
• Replace relay.
Troubleshooting the Up Circuit
NOTE: Refer to the preceding wiring diagrams for test points when troubleshooting the electrical systems. Test points are
specified by number.
Step Test Procedure Test Result
Step 1: Check for
battery voltage at
point 8.
1. Connect voltmeter red lead to point 8
and black lead to ground.
2. Press the up tilt button.
Battery voltage measured:
• Go to step 2.
No battery voltage measured:
• Go to step 3.
Step 2: Check for
battery voltage at
point 9.
Connect voltmeter red lead to point 9 and
black lead to ground.
Battery voltage measured:
• Go to step 5.
No battery voltage measured:
• There is an open circuit between point 9 and positive (+)
battery terminal.
• Check for loose or corroded connections.
• Check wires for open.
Step 3: Check for
battery voltage at
point 7.
1. Connect voltmeter red lead to point 7
and black lead to ground.
2.
Press the up tilt button.
Battery voltage measured:
• Wire is open between points 7 and 8.
No battery voltage measured:
• Go to step 4.
Power Tilt
Page 5B-16 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017