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
The responsibilities listed above are general and in no way a complete listing of the rules and regulations pertaining to the EPA
laws on exhaust emissions for marine products. For more detailed information on this subject, you may contact the following
location:
EP
A INTERNET WEB SITE: http://www.epa.gov/otaq/marinesi.htm
Manufacturer's Certification 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 - Idle speed
b - Engine horsepower
c - Piston displacement
d - Engine power in kilowatts
e - Date of manufacture
f - US EPA engine family name
g - Regulated emissions limit for the engine family
h - Regulated emissions limit for the engine family
i - Recommended spark plug and gap
j - Percent of fuel line permeation
Service Replacement Certification Label
IMPORTANT:
By federal law, it is required that all 1998 and newer Mercury Marine outboards have a visible and legible
emission certification label. If this label is missing or damaged, contact Mercury Marine Service for a replacement.
Removal
Remove all remaining pieces of the damaged or illegible label. Do not install new label over the old label. Use a suitable solvent
to remove any traces of the old label adhesive from the display location.
Date Code Identification
Cut and remove a "V" notch through the month of engine manufacture before installing the new label. The month of
manufacture can be found on the old label. If the label is missing or the date code illegible, contact Mercury Marine Technical
Service for assistance.
a - "V" notch
b - Month of
manufacture
Installation
Install the label on a clean surface in the original factory location.
SPARK PLUG:
GAP:
EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
CALIFORNIA AND U.S. EPA
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE,
SPECIFICATIONS, AND ADJUSTMENTS
IDLE SPEED (in gear):
FAMILY:
HC+NOx:FEL:
LOW PERM/HIGH PERM:
g/kWh
hp
L
e
d
c
b
a
f
g
h
i
HC+NOx:FEL:
g/kWh
hp
L
CO FEL:
g/kWh
kw
g/kWh
j
43210
Emission Control
Information
JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC
THIS ENGINE CONFORMS TO (YEAR) CALIFORNIA AND U.S. EPA
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNERS MANUAL FOR MAINTENANCE,
SPECIFICATIONS, AND ADJUSTMENTS
IDLE SPEED (in gear): XXX RPM
FAMILY: -----.XXXXXX
XXX HP
PART NO.
37-XXXXXX
XXXX cc
FEL: XX.XXXX g/kWh
TIMING (IN DEGREES): XXXXXXXXX
SPARK PLUG: XXXXXXXX
GAP: X.X MM (X.X IN.)
COLD VALVE
CLEARANCE (mm)
INTAKE: 0.XX - 0.XX MM
EXHAUST: 0.XX - 0.XX MM
a
b
11184
General Information
Page 1C-16 © 2018 Mercury Marine 90-8M0125265 eng NOVEMBER 2017