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
Detonation
Detonation in a 4‑cycle engine resembles the pinging heard in an automobile engine. It can be otherwise described as a tin‑like
rattling or plinking sound.
Detonation is the explosion of the unburned fuel/air charge after the spark plug has fired. Detonation creates severe shock
waves in the engine. These shock waves often find or create a weakness: the dome of a piston, cylinder head or gasket, piston
rings or piston ring lands, piston pin, and roller bearings.
A few of the most common causes of detonation in a marine 4‑cycle application are as follows:
•
Over‑advanced ignition timing
• Use of low octane gasoline
• Propeller pitch too high: engine RPM below recommended maximum range
• Lean fuel mixture at, or near, wide‑open throttle
• Spark plugs: heat range too hot, incorrect reach, cross‑firing
• Deteriorated or inadequate engine cooling system
• Combustion chamber deposits: result in higher compression ratio
Detonation usually can be prevented if:
• The engine is correctly set up
• Regular maintenance is scheduled
Elevation, Weather, and Climate
Elevation, weather, and climate changes affect engine performance because an engine's power depends upon the density of
the air that it consumes. Air density, in turn, is dependent upon the ambient air temperature, the barometric pressure, and the
humidity (water vapor) content. Loss of performance can therefore be caused by:
• Higher elevations
• Higher temperatures
• Low barometric pressures
• High humidity
For optimum engine performance under changing conditions, it is essential that the engine be propped to allow the engine to
operate at or near the top end of the specified maximum RPM range with a normal boat load during your normal boating
weather conditions. In most cases, recommended RPM can be achieved by changing to a lower pitch propeller.
Propeller Selection
IMPORTANT: The engines covered in this manual are equipped with an RPM rev‑limiter that is set to an upper RPM limit. This
limit, which is slightly above the normal operating range of the engine, helps prevent damage from excessive engine RPM.
Once the RPM returns to the recommended operating RPM range, normal engine operation resumes.
The boat manufacturer and the selling dealer are responsible for equipping the power package with the correct propeller. Refer
to Mercury Marine's web page https://www.mercurymarine.com/en/us/propellers/selector/#/step‑one
.
Select a propeller that will allow the engine power package to operate at or near the top end of the recommended WOT
operating RPM range with a normal load.
If full‑throttle operation is below the recommended range, the propeller must be changed to prevent loss of performance and
possible engine damage. On the other hand, operating an engine above the recommended operating RPM range will cause
higher than normal wear and damage.
After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch.
•
Warmer weather and greater humidity cause a loss of RPM.
• Operating in a higher elevation causes a loss of RPM.
• Operating with a dirty boat bottom causes a loss of RPM.
• Operating with increased load (additional passengers, pulling skiers) causes a loss of RPM.
For better acceleration, such as is needed for waterskiing, use the next lower pitch propeller. When not pulling skiers, do not
operate at full throttle when using the lower pitch propeller.
Water Absorption
It is imperative that all through‑the‑hull fasteners be coated with a quality marine sealer at time of installation. Water intrusion
into the transom core and/or inner hull will result in additional boat weight (reduced boat performance), hull decay, and eventual
structural failure.
Weight Distribution (Passengers and Gear) Inside the Boat
Shifting weight to rear (stern):
General Troubleshooting
90-8M0125265 eng NOVEMBER 2017 © 2018 Mercury Marine Page 1E-3