M 75 90 115 - FourStroke - 2.1L

80/100/115 FourStroke 2.
1L (EU)
75/90/115
75/90/115 FourStroke 2.1L

FourStroke 2.1L
80/100/115
FourStroke 2.1L
(EU)
S ERVI CE MANUAL
90-8M0082471 JULY 2014

www.mercurymarine.com.au www.mercurymarine.com www.marinepower.com
41-71 Bessemer Drive P.O. Box 1939 Parc Industriel de Petit-Rechain
Dandenong South, Victoria 3175 Australia Fond du Lac, WI 54936-1939 USA B-4800 Verviers, Belgium
Mercury Marine. All rights reserved. Printed in U.S.A.

Starting serial number 2B095049
Notice to Users of This Manual
Throughout this publication, warnings, cautions, and notices (accompanied by the International HAZARD Symbol !
) are
used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if
performed incorrectly or carelessly. Observe them carefully!
These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when
performing the service, plus common sense operation, are major accident prevention measures.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure.
IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.
This manual has been written and published by the Service Department of Mercury Marine to aid our dealers mechanics and
company service personnel when servicing the products described herein. We reserve the right to make changes to this
manual without prior notification.
It is assumed that these personnel are familiar with marine product servicing procedures. Furthermore, it is assumed that they
have been trained in the recommended service procedures of Mercury Marine Power Products, including the use of mechanics
common hand tools and the special Mercury Marine or recommended tools from other suppliers.
We could not possibly know of and advise the marine trade of all conceivable procedures and of the possible hazards and/or
results of each method. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the
manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered.
All information, illustrations, and specifications contained in this manual are based on the latest product information available at
the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service
these products.
Refer to dealer service bulletins, operation maintenance and warranty manuals, and installation manuals for other pertinent
information concerning the products described in this manual.
Precautions
It should be kept in mind, while working on the product, that the electrical and ignition systems are capable of violent and
damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be
grounded or touched by the mechanic, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental
entrance of foreign material into the cylinders which could cause extensive internal damage when the engine is started.
During any maintenance procedure, replacement fasteners must have the same measurements and strength as those
removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts
use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners
can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the
same locations whenever possible. Where the fasteners are not satisfactory for reuse, care should be taken to select a
replacement that matches the original.
Replacement Parts
Use of parts other than the recommended service replacement parts will void the warranty on those parts that are damaged as
a result.
! WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with
federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system
components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and
tighten all components.
Page i
Cleanliness and Care of Product
A Mercury Marine Power Product is a combination of many machined, honed, polished, and lapped surfaces with tolerances
measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. It
should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair
procedure. This is considered standard shop practice even if not specifically stated.
Whenever components are removed for service, they should be retained in order. At the time of installation, they should be
installed in the same locations and with the same mating surfaces as when removed.
Personnel should not work on or under an engine that is suspended. Engines should be attached to work stands, or lowered to
ground as soon as possible.
Copyright and Trademark Information

MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited.
Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, Kplanes, Mariner, MerCathode, MerCruiser,
Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing,
MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, SportJet, Verado, VesselView, Zero Effort, Zeus, #1 On the
Water and We're Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of Brunswick
Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.
Page ii
1
Manual Outline
Important Information
1 - Important Information
A - Master Specifications
B - Maintenance
C - General Information
Electrical
2
3
D - Outboard Motor Installation
E - Storage Fuel Systems
2 - Electrical
A - Ignition
B - Charging and Starting Systems
C - Timing, Synchronizing, and Adjustments
Powerhead
4
5
D - Accessory Wire Diagrams
E - Fault List Midsection
3 - Fuel Systems
A - Theory of Operation
B - Troubleshooting and Diagnostics
C - Service Procedures
Gear Housing
6
D - Emissions
4 - Powerhead
A - Cylinder Block/Crankcase
Control Linkage and Attachments
7
B - Cylinder Head
C - Lubrication
D - Cooling
Color Diagrams
8
5 - Midsection
A - Clamp/Swivel Brackets and Driveshaft Housing
B - Adapter Plate and Driveshaft Housing
C - Power Trim
6 - Gear Housing
A - Standard Right-Hand Rotation Gear Housing
B - Command Thrust Right-Hand Rotation Gear
Housing
C - Command Thrust Left-Hand Rotation Gear
Housing
7 - Control Linkage and Attachments
A - Throttle/Shift Linkage
B - Big Tiller
8 - Color Diagrams
A - Color Diagrams
Page iii
Page iv
Master Specifications
1
Section 1A - Master Specifications A
Table of Contents
Master Specifications.........................................................1A-2 Command Thrust LeftHand Gear Housing
General Specifications................................................1A-2 Specifications.......................................................... 1A-9
Ignition Specifications................................................. 1A-3 Propeller Information..........................................................1A-9
Fuel System Specifications.........................................1A-3 75 (80 EU) EFI FourStroke 2.1L Standard Gearcase
Charging and Starting Specifications..........................1A-4 Propeller Information Chart..................................... 1A-9
Cylinder Block/Crankcase Specifications................... 1A-5 90 (100 EU) EFI FourStroke 2.1L Standard Gearcase
Cylinder Head Specifications......................................1A-6 Propeller Information Chart................................... 1A-10
Cooling Specifications................................................ 1A-7 115 (115 EU) EFI FourStroke 2.1L Standard
Lubrication System Specifications.............................. 1A-7 Gearcase Propeller Information Chart.................. 1A-12
MidSection Specifications..........................................1A-7 90 (100 EU) EFI FourStroke 2.1L Command Thrust
Power Trim Specifications.......................................... 1A-8 Propeller Information Chart................................... 1A-13
Standard Gear Housing Specifications.......................1A-8 115 (115 EU) EFI FourStroke 2.1L Command Thrust
Command Thrust RightHand Gear Housing Propeller Information Chart................................... 1A-15
Specifications.......................................................... 1A-8
90-8M0082471 JULY 2014 Page 1A-1

General Specifications
Model Specifications
85.8 kW (115 hp)
74.5 kW (100 hp)
Kilowatts (horsepower) 67.1 kW (90 hp)
59.6 kW (80 hp)
55.9 kW (75 hp)
Number of cylinders 4
Outboard weight
Standard gearcase models dry weight L 163 kg (359 lb)
Standard gearcase models dry weight XL 172 kg (380 lb)
Command Thrust models L 163 kg (359 lb)
Command Thrust models XL 172 kg (380 lb)
Displacement 2.061 L (126 cid)
Cylinder bore 90 mm (3.5 in.)
Stroke 81 mm (3.2 in.)
RPM
Idle (in gear) 700 50 RPM
WOT 75/80 45005500 RPM
WOT 90/100/115 50006000 RPM
Fuel system Computer controlled multiport electronic fuel injection
Ignition system SmartCraft engine control module (ECM) digital inductive
Spark plug type NGK ZFR5F
Spark plug gap 0.8 mm (0.032 in.)
Spark plug hex size 16 mm
Spark plug torque 27 Nm (20 lbft)
Spark plug hole size 14 mm
Firing order 1342
Charging system 35 A stator with watercooled voltage regulator
Exhaust system Throughthepropeller
Cooling system Watercooled thermostat
Valve opening temperature 46.151.7 C (115125 F)
Operating range 5070 C (122158 F)
Lubrication system
Engine capacity with filter replacement 5.2 L (5.5 US qt)
Trim system
Maximum tilt range 73 (6 to 67)
Maximum trim range 20 (6 to 14)
Page 1A-2 90-8M0082471 JULY 2014

Ignition Specifications
Full throttle RPM 75/80 45005500
Full throttle RPM 90/100/115 50006000
Idle RPM in neutral 700 50
Ignition type Digital inductive
Firing order 1342
Ignition timing at idle Approximately 2 BTDC; ECM controlled
Ignition timing at WOT ECM controlled
ECM overspeed limiter
75/80 Activates at 5650 RPM
90/100/115 Activates at 6150 RPM
Fuel System Specifications

Automotive unleaded with a minimum pump posted octane rating of 87 (90
Type of fuel
RON)
Approximate fuel pressure at idle 280310 kPa (40.645.0 psi)
Approximate fuel pressure engine not running 340370 kPa (49.353.7 psi)
Fuel filtration
Fuel inlet 20 microns
High pressure 20 microns
90-8M0082471 JULY 2014 Page 1A-3

Charging and Starting Specifications

Charging and Starting Specifications At 20 C (68 F)
Alternator typeStator under flywheel Three phase stator coil (18 pole)
Stator coil output
At 1000 RPM 23 A
At 5000 RPM 35 A
Stator coil outputPeak voltage
At 400 RPM (cranking) in neutralNo load 1218 V
At 1500 RPMNo Load 4565 V
Stator coil resistance 0.20.4
Rectifier regulator outputPeak voltage
At 1500 RPMNo load 14.014.8 V
Fuse 40 A
Starter type Positive engagement
Output 1.2 kW (12 V)
Rating 30 seconds
Reduction gear ratio 6:1
Ampere draw under load 130225 A
Ampere draw under no load 5070 A
Battery rating
For operation below 0 C (32 F) 1000 marine cranking amps (MCA) or 800 cold cranking amps (CCA)
Ampere hours (Ah) 65
Page 1A-4 90-8M0082471 JULY 2014

Cylinder Block/Crankcase Specifications

Compression ratio 10:1
Standard bore finished hone 90.00 mm (3.543 in.)
Stroke 82.00 mm (3.228 in.)
Flatness 0.1 mm (0.0039 in.)
Cylinder deck
Surface tolerance Smooth and free of machine marks, nicks, scratches
Crankcase deck
Cylinder bore maximum taper (service) 0.030 mm (0.0011 in.)
Cylinder bore maximum out of round (service) 0.050 mm (0.0019 in.)
A 52.98852.996 mm (2.08622.0864 in.)
Cylinder block main bearing journal
B 52.99753.004 mm (2.08652.0867 in.)
(letter)
C 53.00553.012 mm (2.08682.0870 in.)
Crankshaft main bearing journal A 47.99348.001 mm (1.88951.8898 in.)

(letter) B 47.98547.993 mm (1.88921.8898 in.)
C 43.99244.000 mm (1.73201.7323 in.)
Crankshaft connecting rod journal
D 43.98443.992 mm (1.73171.7320 in.)
Crankshaft end play 0.05080.3048 mm (0.0020.012 in.)
Crankshaft runout 0.025 mm (0.0009 in.)
Crankshaft main bearing oil clearance 0.0500.084 mm (0.00190.0033 in.)
Connecting rod piston pin bore diameter 20.01620.026 mm (0.78810.7884 in.)
Journal grade "I" 47.00047.008 mm (1.85041.8507 in.)
Connecting rod crankshaft pin diameter
Journal grade "0" 47.00847.016 mm (1.85071.8510 in.)
Connecting rod bearing oil clearance 0.0310.059 mm (0.00120.0023 in.)
Piston skirt standard diameter 89.94289.952 mm (3.54103.5414 in.)
Minimum 0.048 mm (0.0018 in.)
Piston to cylinder clearance
Maximum 0.073 mm (0.0028 in.)
Piston pin bore diameter 19.99620.011 mm (0.78730.7878 in.)
Piston pin diameter 19.99620.001 mm (0.78730.7874 in.)
First 1.011.03 mm (0.0398 0.0405 in.)
Piston ring groove width Second 1.011.03 mm (0.0398 0.0405 in.)
Third 2.012.03 mm (0.07920.0799 in.)
First 0.970.99 mm (0.03820.0389 in.)
Piston ring thickness
Second 0.970.99 mm (0.03820.0389 in.)
First 0.020.06 mm (0.00070.0023 in.)
Piston ring side clearance
Second 0.020.06 mm (0.00070.0023 in.)
First 0.270.37 mm (0.01070.0145 in.)
Piston ring end gap Second 0.420.62 mm (0.01660.0244 in.)
Third (lower ring only) 0.20.7 mm (0.00790.0275 in.)
90-8M0082471 JULY 2014 Page 1A-5

Cylinder Head Specifications

Maximum warp (for cylinder head) 0.1 mm (0.0039 in.)
Maximum warp within 100 mm (3.937 in.) in all
0.05 mm (0.0019 in.)
directions
Deck
0.025 mm (0.0009 in.)
directions
Minimum datum height (combustion chamber) 4.8 mm (0.1889 in.)
Number of valves 8
Number of valves per cylinder 2
29.00029.021 mm
Camshaft bearing inside diameter (cylinder head)
(1.14181.1425 in.)
19.975 0.025 mm
Cylinder head camshaft center bearing thrust face
(0.7864 0.0009 in.)
28.97 0.01 mm
Camshaft bearing journal
(1.1405 0.0004 in.)
Camshaft lobe height (115 HP Intake 47.2046 mm (1.8584 in.)

and 80 Jet) Exhaust 47.555 mm (1.8722 in.)
Intake 45.1377 mm (1.777 in.)
Camshaft lobe height (7590 HP)
Exhaust 47.0666 mm (1.853 in.)
0.075 0.025 mm
Intake
Camshaft to roller clearance (0.003 0.001 in.)
(lash) (cold) 0.150 0.025 mm
Exhaust
(0.006 0.001 in.)
Valve seat angles (referenced Intake 30, 44 0.25, 60

from the valve axis) Exhaust 25, 39 0.25, 53, 67
1.00 0.1 mm
Intake (44)
Valve seat width (0.0394 0.0039 in.)
Exhaust (39) 1.50 0.1 mm (0.059 0.004 in.)
Uncompressed 54.62 mm (2.150 in.)
240 12 N (53.95 2.70 lbf)
Compressed to 47.08 mm (1.854 in.)
Valve spring height spring pressure
760 34 N (170.85 7.64 lbf)
spring pressure
Intake 45.2 0.1 mm (1.780 0.004 in.)
Valve outside diameter
Exhaust 35 0.1 mm (1.378 0.004 in.)
Intake 45
Valve face angle
Exhaust 40
0.875 0.2 mm
Intake
(0.0345 0.0078 in.)
Valve margin width
1.45 0.2 mm
Exhaust
(0.0571 0.0078 in.)
6.97 0.008 mm
Intake
(0.2744 0.0003 in.)
Valve stem diameter
6.96 0.008 mm
Exhaust
(0.2740 0.0003 in.)
Valve stem runout (service limit
Intake and exhaust 0.03 mm (0.0012 in.)
measured at valve face)
Page 1A-6 90-8M0082471 JULY 2014


121.96 0.25 mm
Intake
(4.8016 0.01 in.)
Valve height
122.44 0.25 mm
Exhaust
(4.8204 0.01 in.)
7.0017.021 mm
Valve guide bore inside diameter Intake and exhaust
(0.27570.2764 in.)
0.0230.059 mm
Intake
Valve stem to valve guide (0.00090.0023 in.)
clearance 0.0330.069 mm
Exhaust
(0.00120.0027 in.)
15.1 0.25 mm
Valve guide height Intake and exhaust
(0.595 0.0098 in.)
Cooling Specifications
Cooling system Watercooled thermostat control
At 650 RPM (idle) 530 kPa (0.74.4 psi)
Water pressure
At 5800 RPM (WOT) 80300 kPa (11.643.5 psi)
Valve stroke (minimum) at full open temperature 7.62 mm (0.30 in.)
Thermostat Start to opening temperature 46.151.7 C (115125 F)
Full open temperature 65.6 C (150 F)
Lubrication System Specifications

5.2 L (5.5 US qt) NMMA FCW
Engine capacity with filter replacement
SAE 10W30
Quicksilver P/N 8M0065103
Oil filter
MPP P/N 8M0065104
At idle RPM (normal oil warm) 90180 kPa (1326 psi)
At WOT RPM (normal oil warm) 300400 kPa (43.558 psi)
Oil pressure
At idle RPM (minimum) 35 kPa (5 psi)
At WOT RPM (minimum) 185 kPa (27 psi)
MidSection Specifications
Recommended Transom Height
Short Shaft 51 cm (20 in.)
Long Shaft 64 cm (25 in.)
Steering Pivot Range 60
Full Tilt Up Angle 71
Allowable Transom Thickness (Max) 76.2 mm (3 in.)
90-8M0082471 JULY 2014 Page 1A-7

Power Trim Specifications

Trim up circuit pressure, minimum 19,300 kPa (2800 psi)
Tilt relief pressure (up) 37206830 kPa (540990 psi)
Trim down circuit pressure 34805860 kPa (505850 psi)
System fluid Power Trim and Steering Fluid or Automatic Transmission Fluid (ATF) (Dexron III)
Standard Gear Housing Specifications

RightHand Gear Housing Specifications (Standard)
Gear ratio 2.07:1 (14/29 teeth)
Gear housing capacity 800 ml (27.1 fl oz)
Gear lubricant type High Performance Gear Lubricant
Propeller shaft runout 0.152 mm (0.006 in.)
Propeller shaft end play 0.1271.905 mm (0.0050.075 in.)
Pinion height 0.635 mm (0.025 in.)
Forward gear backlash 0.3300.483 mm (0.0130.019 in.)
Reverse gear backlash N/A
Water pressure
At 5800 RPM (WOT) 80300 kPa (11.643.5 psi)
Gear housing leak test (without gear lubricant, 15 minutes without leakage) 103.4 kPa (15 psi)
Command Thrust RightHand Gear Housing Specifications

RightHand Gear Housing Specifications (Command Thrust)
Water pressure
At 5800 RPM (WOT) 80300 kPa (11.643.5 psi)
Page 1A-8 90-8M0082471 JULY 2014

Command Thrust LeftHand Gear Housing Specifications

LeftHand Gear Housing Specifications (Command Thrust)
Water pressure
At 5800 RPM (WOT) 80300 kPa (11.643.5 psi)
Propeller Information
75 (80 EU) EFI FourStroke 2.1L Standard Gearcase Propeller Information Chart
Wideopen throttle RPM: 45005500
Recommended transom height: 50.8 cm (20 in.), 63.5 cm (25 in.)
Gear reduction: 2.07:1
Righthand rotation (RH) standard
No. of Approx. Gross Approx. Boat Propeller Part

Diameter Pitch Model Speed Range
Blades Boat Wgt. Length Number
Up to 591 kg Up to 4.9 m 7495 km/h
13.5 26 3 Laser II 4816996A46
(1300 lb) (16 ft) (4659 MPH)
Up to 682 kg Up to 5.2 m 68 89 km/h
13.5 24 3 Laser II 4816994A46
(1500 lb) (17 ft) (4255 MPH)
545727 kg 4.65.2 m 6384 km/h
13.75 23 4 Trophy 48825936A46
(12001600 lb) (1517 ft) (3952 MPH)
Black Max 545727 kg 4.65.2 m 6384 km/h
12.5 23 3 4877350A45
Aluminum (12001600 lb) (1517 ft) (3952 MPH)
545773 kg 4.65.4 m 6080 km/h
13.5 22 3 Laser II 4816992A46
(12001700 lb) (1518 ft) (3750 MPH)
591864 kg 4.85.4 m 5576 km/h
13.75 21 4 Trophy 48825934A47
(13001900 lb) (1618 ft) (3447 MPH)
636864 kg 4.85.4 m 5576 km/h
13.25 21 3 Laser II 48899006A46
(14001900 lb) (1618 ft) (3447 MPH)
Black Max 636864 kg 4.85.8 m 5576 km/h
12.75 21 3 4877348A45
636955 kg 4.85.4 m 5072 km/h
13.25 20 3 Laser II 4816990A46
(14002100 lb) (1619 ft) (3145 MPH)
6821045 kg 4.96.1 m 4768 km/h
13.75 19 4 Trophy 48825932A46
(15002300 lb) (1620 ft) (2942 MPH)
6821045 kg 4.96.1 m 4768 km/h
13.25 19 3 Laser II 48899004A46
(15002300 lb) (1620 ft) (2942 MPH)
6821045 kg 4.96.1 m 4768 km/h
12.8 19 4 Spitfire 488M8026600
(15002300 lb) (1620 ft) (2942 MPH)
Black Max 6821045 kg 4.96.1 m 4768 km/h
13 19 3 4877346A45
90-8M0082471 JULY 2014 Page 1A-9


7271136 kg 5.26.4 m 5071 km/h
13 18 3 Vengeance 4816988A46
(16002500 lb) (1721 ft) (2640 MPH)
7731318 kg 5.26.7 m 3760 km/h
13.75 17 4 Trophy 48825930A46
(17002900 lb) (1722 ft) (2337 MPH)
7731318 kg 5.26.7 m 3760 km/h
12.8 17 4 Spitfire 488M8026590
(17002900 lb) (1722 ft) (2337 MPH)
Black Max 7731318 kg 5.26.7 m 3760 km/h
13.25 17 3 4877344A45
8641545 kg 5.37.0 m 3255 km/h
13.13 16 3 Vengence 4816986A46
(19003400 lb) (1823 ft) (2034 MPH)
Black Max 8641545 kg 5.37.0 m 3255 km/h
13.25 16 3 48854360A45
9551773 kg 5.87.3 m 2950 km/h
13.25 15 3 Vengeance 48854354A46
(21003900 lb) (1924 ft) (1831 MPH)
9551773 kg 5.87.3 m 2950 km/h
12.8 15 4 Spitfire 488M8026580
(21003900 lb) (1924 ft) (1831 MPH)
Black Max 9551773 kg 5.87.3 m 2950 km/h
13.75 15 3 4877342A45
10452136 kg 6.17.6 m 2445 km/h
13.38 14 3 Vengeance 4817314A46
(23004700 lb) (2025 ft) (1528 MPH)
Black Max 10452136 kg 6.17.6 m 2445 km/h
13.88 14 3 48854352A45
11362773 kg 6.48.2 m 1942 km/h
13.8 13 4 Spitfire Pontoon 488026570
(25006100 lb) (2127 ft) (1226 MPH)
Black Max 11362773 kg 6.48.2 m 1942 km/h
14 13 3 4877340A45
13183409 kg 1637 km/h
14 12 3 Vengeance 6.7+ m (22+ ft) 4817312A46
(29007500 lb) (1023 MPH)
15455091 kg 1132 km/h
13.8 11 4 Spitfire Pontoon Pontoon 488M8026560
(340011200 lb) (720 MPH)
Black Max 1727+ kg 132 km/h
14 11 3 House/work 4877338A45
Aluminum (3800+ lb) (120 MPH)

13.5 26 3 Laser II 4816996A46
(1400 lb) (16 ft) (5365 MPH)
Up to 682 kg Up to 5.2 m 77 97 km/h
13.5 24 3 Laser II 4816994A46
(1500 lb) (17 ft) (4860 MPH)
591727 kg 4.65.2 m 7292 km/h
13.75 23 4 Trophy 48825936A46
(13001600 lb) (1517 ft) (4557 MPH)
Black Max 591727 kg 4.65.2 m 7292 km/h
12.5 23 3 4877350A45
Page 1A-10 90-8M0082471 JULY 2014


591773 kg 4.65.4 m 6989 km/h
13.5 22 3 Laser II 4816992A46
(13001700 lb) (1518 ft) (4355 MPH)
636864 kg 4.85.4 m 6484 km/h
13.75 21 4 Trophy 48825934A47
(14001900 lb) (1618 ft) (4052 MPH)
636864 kg 4.85.4 m 6484 km/h
13.25 21 3 Laser II 48899006A46
(14001900 lb) (1618 ft) (4052 MPH)
Black Max 636864 kg 4.85.8 m 6484 km/h
12.75 21 3 4877348A45
682955 kg 4.85.4 m 6079 km/h
13.25 20 3 Laser II 4816990A46
(15002100 lb) (1619 ft) (3749 MPH)
7271045 kg 4.96.1 m 5576 km/h
13.75 19 4 Trophy 48825932A46
(16002300 lb) (1620 ft) (3447 MPH)
7271045 kg 4.96.1 m 5576 km/h
13.25 19 3 Laser II 48899004A46
(16002300 lb) (1620 ft) (3447 MPH)
7271045 kg 4.96.1 m 5576 km/h
12.8 19 4 Spitfire 488M8026600
(16002300 lb) (1620 ft) (3447 MPH)
Black Max 7271045 kg 4.96.1 m 5576 km/h
13 19 3 4877346A45
7731136 kg 5.26.4 m 5071 km/h
13 18 3 Vengeance 4816988A46
(17002500 lb) (1721 ft) (3144 MPH)
8181273 kg 5.26.7 m 4566 km/h
13.75 17 4 Trophy 48825930A46
(18002800 lb) (1722 ft) (2841 MPH)
8181273 kg 5.26.7 m 4566 km/h
12.8 17 4 Spitfire 488M8026590
(18002800 lb) (1722 ft) (2841 MPH)
Black Max 8181273 kg 5.26.7 m 4566 km/h
13.25 17 3 4877344A45
9091455 kg 5.37.0 m 4061 km/h
13.13 16 3 Vengence 4816986A46
(20003200 lb) (1823 ft) (2538 MPH)
Black Max 9091455 kg 5.37.0 m 4061 km/h
13.25 16 3 48854360A45
10001682 kg 5.87.3 m 3556 km/h
13.25 15 3 Vengeance 48854354A46
(22003700 lb) (1924 ft) (2235 MPH)
10001682 kg 5.87.3 m 3556 km/h
12.8 15 4 Spitfire 488M8026580
(22003700 lb) (1924 ft) (2235 MPH)
Black Max 10001682 kg 5.87.3 m 3556 km/h
13.75 15 3 4877342A45
10912000 kg 6.17.6 m 3151 km/h
13.38 14 3 Vengeance 4817314A46
(24004400 lb) (2025 ft) (1932 MPH)
Black Max 10912000 kg 6.17.6 m 3151 km/h
13.88 14 3 48854352A45
12272409 kg 6.48.2 m 2647 km/h
(27005300 lb) (2127 ft) (1629 MPH)
Black Max 12272409 kg 6.48.2 m 2647 km/h
14 13 3 4877340A45
14093045 kg 2142 km/h
14 12 3 Vengeance 6.7+ m (22+ ft) 4817312A46
(31006700 lb) (1326 MPH)
15914091 kg 1637 km/h
(35009000 lb) (1023 MPH)
90-8M0082471 JULY 2014 Page 1A-11


14 11 3 House/work 4877338A45

13.5 26 3 Laser II 4816996A46
(1600 lb) (16 ft) (5365 MPH)
13.5 24 3 Laser II 4816994A46
(1800 lb) (17 ft) (4860 MPH)
727955 kg 4.65.2 m 7292 km/h
13.75 23 4 Trophy 48825936A46
(16002100 lb) (1517 ft) (4557 MPH)
Black Max 727955 kg 4.65.2 m 7292 km/h
12.5 23 3 4877350A45
7731000 kg 4.65.5 m 6989 km/h
13.5 22 3 Laser II 4816992A46
(17002200 lb) (1518 ft) (4355 MPH)
8181091 kg 4.85.5 m 6484 km/h
13.75 21 4 Trophy 48825934A47
(18002400 lb) (1618 ft) (4052 MPH)
8181091 kg 4.85.5 m 6484 km/h
13.25 21 3 Laser II 48899006A46
(18002400 lb) (1618 ft) (4052 MPH)
Black Max 8181091 kg 4.85.5 m 6484 km/h
12.75 21 3 4877348A45
8641182 kg 4.85.8 m 6079 km/h
13.25 20 3 Laser II 4816990A46
(19002600 lb) (1619 ft) (3749 MPH)
9091318 kg 4.96.1 m 5576 km/h
13.75 19 4 Trophy 48825932A46
(20002900 lb) (1620 ft) (3447 MPH)
9091318 kg 4.96.1 m 5576 km/h
13.25 19 3 Laser II 48899004A46
(20002900 lb) (1620 ft) (3447 MPH)
9091318 kg 4.96.1 m 5576 km/h
12.8 19 4 Spitfire 488M8026600
(20002900 lb) (1620 ft) (3447 MPH)
Black Max 9091318 kg 4.96.1 m 5576 km/h
13 19 3 4877346A45
10001455 kg 5.26.4 m 5071 km/h
13 18 3 Vengeance 4816988A46
(22003200 lb) (1721 ft) (3144 MPH)
10451636 kg 5.26.7 m 4566 km/h
13.75 17 4 Trophy 48825930A46
(23003600 lb) (1722 ft) (2841 MPH)
10451636 kg 5.26.7 m 4566 km/h
12.8 17 4 Spitfire 488M8026590
(23003600 lb) (1722 ft) (2841 MPH)
Black Max 10451636 kg 5.26.7 m 4566 km/h
13.25 17 3 4877344A45
11361864 kg 5.37.0 m 4061 km/h
13.13 16 3 Vengence 4816986A46
(25004100 lb) (1823 ft) (2538 MPH)
Black Max 11361864 kg 5.37.0 m 4061 km/h
13.25 16 3 48854360A45
Page 1A-12 90-8M0082471 JULY 2014


12732136 kg 5.87.3 m 3556 km/h
13.25 15 3 Vengeance 48854354A46
(28004700 lb) (1924 ft) (2235 MPH)
12732136 kg 5.87.3 m 3556 km/h
12.8 15 4 Spitfire 488M8026580
(28004700 lb) (1924 ft) (2235 MPH)
Black Max 12732136 kg 5.87.3 m 3556 km/h
13.75 15 3 4877342A45
14092545 kg 6.17.6 m 3151 km/h
13.38 14 3 Vengeance 4817314A46
(31005600 lb) (2025 ft) (1932 MPH)
Black Max 14092545 kg 6.17.6 m 3151 km/h
13.88 14 3 48854352A45
15913045 kg 6.48.2 m 2647 km/h
(35006700 lb) (2127 ft) (1629 MPH)
Black Max 15913045 kg 6.48.2 m 2647 km/h
14 13 3 4877340A45
17733864 kg 2142 km/h
14 12 3 Vengeance 6.7+ m (22+ ft) 4817312A46
(39008500 lb) (1326 MPH)
20455227 kg 1637 km/h
(4500115000 lb) (1023 MPH)
14 11 3 House/work 4877338A45
90 (100 EU) EFI FourStroke 2.1L Command Thrust Propeller Information Chart
Righthand rotation (RH), Lefthand rotation (LH)
Aluminum (al)

682864 kg 4.35.2 m 6179 km/h 48825864A47
14.62 23 3 Tempest Plus
(15001900 lb) (1417 ft) (3849 MPH) 48825865A47 (LH)
682864 kg 4.35.2 m 6179 km/h
13.25 23 5 High Five 48815762A46
(15001900 lb) (1417 ft) (3849 MPH)
682864 kg 4.35.2 m 6179 km/h 48825906A48
14.00 23 4 VenSura
(15001900 lb) (1417 ft) (3849 MPH) 48825907A48 (LH)
682864 kg 4.35.2 m 6179 km/h 4816320A46
13.50 23 3 Vengeance
(15001900 lb) (1417 ft) (3849 MPH) 4816321A46 (LH)
Black Max 682864 kg 4.35.2 m 6179 km/h
14.00 23 3 48832834A45
7271000 kg 4.35.5 m 5676 km/h
13.50 22 3 Enertia 48899202A46
(16002200 lb) (1418 ft) (3547 MPH)
7271000 kg 4.35.5 m 5676 km/h
14.62 22 3 Tempest Plus 488M8026820
(16002200 lb) (1418 ft) (3547 MPH)
7271091 kg 4.65.8 m 5172 km/h 48899002A46
13.80 21 3 Enertia
(16002400 lb) (1519 ft) (3245 MPH) 48899003A46 (LH)
7271091 kg 4.65.8 m 5172 km/h 48825862A47
(16002400 lb) (1519 ft) (3245 MPH) 48825863A47 (LH)
7271091 kg 4.65.8 m 5172 km/h
13.25 21 5 HighFive 48815760A46
(16002400 lb) (1519 ft) (3245 MPH)
90-8M0082471 JULY 2014 Page 1A-13


7271091 kg 4.65.8 m 5172 km/h 48825902A48
14.00 21 4 VenSura
(16002400 lb) (1519 ft) (3245 MPH) 48825903A48 (LH)
7271091 kg 4.65.8 m 5172 km/h 4816318A46
(16002400 lb) (1519 ft) (3245 MPH) 4816319A46 (LH)
Black Max 7271091 kg 4.65.8 m 5172 km/h
14.25 21 3 48832832A45
8181227 kg 4.65.8 m 4768 km/h
13.75 20 3 Enertia 48899000A46
(18002700 lb) (1519 ft) (2942 MPH)
8641318 kg 4.96.1 m 4364 km/h 48898998A46
14.00 19 3 Enertia
(19002900 lb) (1620 ft) (2740 MPH) 48898999A46 (LH)
8641318 kg 4.96.1 m 4364 km/h 48825860A47
(19002900 lb) (1620 ft) (2740 MPH) 48825861A47 (LH)
8641318 kg 4.96.1 m 4364 km/h
13.25 19 5 HighFive 48815758A46
(19002900 lb) (1620 ft) (2740 MPH)
8641318 kg 4.96.1 m 4364 km/h 48825900A48
14.00 19 4 VenSura
(19002900 lb) (1620 ft) (2740 MPH) 48825901A48 (LH)
8641318 kg 4.96.1 m 4364 km/h 4816316A46
(19002900 lb) (1620 ft) (2740 MPH) 4816317A46 (LH)
Black Max 8641318 kg 4.96.1 m 4364 km/h
14.50 19 3 48832830A45
9551500 kg 4.96.4 m 3960 km/h
14.20 18 3 Enertia 48898996A46
(21003300 lb) (1621 ft) (2437 MPH)
10001773 kg 5.27.0 m 3456 km/h 48898994A46
14.50 17 3 Enertia
(22003900 lb) (1723 ft) (2135 MPH) 48898995A46 (LH)
10001773 kg 5.27.0 m 3456 km/h
14.62 17 3 Tempest Plus 488M8026790
(22003900 lb) (1723 ft) (2135 MPH)
10001773 kg 5.27.0 m 3456 km/h
13.50 17 5 HighFive 48821154A46
(22003900 lb) (1723 ft) (2135 MPH)
10001773 kg 5.27.0 m 3456 km/h 48825898A48
14.25 17 4 VenSura
(22003900 lb) (1723 ft) (2135 MPH) 48825899A48 (LH)
10001773 kg 5.27.0 m 3456 km/h 4816314A46
(22003900 lb) (1723 ft) (2135 MPH) 4816315A46 (LH)
Black Max 10001773 kg 5.27.0 m 3456 km/h
15.00 17 3 48832828A45
10912000 kg 5.57.0 m 3151 km/h
14.70 16 3 Enertia 48898992A46
(24004400 lb) (1823 ft) (1932 MPH)
12272409 kg 5.57.6 m 2647 km/h 48898990A46
15.00 15 3 Enertia
(27005300 lb) (1825 ft) (1629 MPH) 48898991A46 (LH)
12272409 kg 5.57.6 m 2647 km/h
15.25 15 3 Black Max 4878116A45
(27005300 lb) (1825 ft) (1629 MPH)
14092773 kg 6.17.9 m 2342 km/h 48898988A46
15.30 14 3 Enertia
(31006100 lb) (2026 ft) (1426 MPH) 488M0079504 (LH)
15003682 kg 1839 km/h 488M0070074
15.60 13 3 Enertia Pontoon
(33008100 lb) (1124 MPH) 488M0070076 (LH)
Black Max 15003682 kg 1839 km/h
16.00 13 3 Pontoon 4878114A45
Aluminum (33008100 lb) (1124 MPH)
16.00 12 3 Pontoon/Work 4816436A45
2727+ kg 129 km/h 488M0070079
16.00 11 3 Enertia Pontoon/Work
(6000+ lb) (118 MPH) 8M0070077 (LH)
Page 1A-14 90-8M0082471 JULY 2014


Black Max 2727+ kg 129 km/h 4878112A45
16.00 11 3 Pontoon/Work
Aluminum (6000+ lb) (118 MPH) 4878117A40 (LH)
115 (115 EU) EFI FourStroke 2.1L Command Thrust Propeller Information Chart
Righthand rotation (RH), Lefthand rotation (LH)
Aluminum (al)

8641182 kg 4.96.1 m 6179 km/h 48825864A47
(19002600 lb) (1620 ft) (3849 MPH) 48825865A47 (LH)
8641182 kg 4.96.1 m 6179 km/h
13.25 23 5 High Five 48815762A46
(19002600 lb) (1620 ft) (3849 MPH)
8641182 kg 4.96.1 m 6179 km/h 48825906A48
14.00 23 4 VenSura
(19002600 lb) (1620 ft) (3849 MPH) 48825907A48 (LH)
8641182 kg 4.96.1 m 6179 km/h 4816320A46
(19002600 lb) (1620 ft) (3849 MPH) 4816321A46 (LH)
Black Max 8641182 kg 4.96.1 m 6179 km/h
14.00 23 3 48832834A45
9091273 kg 4.96.1 m 5676 km/h
13.50 22 3 Enertia 48899202A46
(20002800 lb) (1620 ft) (3547 MPH)
9091273 kg 4.96.4 m 5676 km/h
14.62 22 3 Tempest Plus 488M8026820
(20002800 lb) (1621 ft) (3547 MPH)
9551409 kg 4.96.4 m 5172 km/h 48899002A46
13.80 21 3 Enertia
(21003100 lb) (1621 ft) (3245 MPH) 48899003A46 (LH)
9551409 kg 4.96.4 m 5172 km/h 48825862A47
(21003100 lb) (1621 ft) (3245 MPH) 48825863A47 (LH)
9551409 kg 4.96.4 m 5172 km/h
13.25 21 5 HighFive 48815760A46
(21003100 lb) (1621 ft) (3245 MPH)
9551409 kg 4.96.4 m 5172 km/h 48825902A48
14.00 21 4 VenSura
(21003100 lb) (1621 ft) (3245 MPH) 48825903A48 (LH)
9551409 kg 4.96.4 m 5172 km/h 4816318A46
(21003100 lb) (1621 ft) (3245 MPH) 4816319A46 (LH)
Black Max 9551409 kg 4.96.4 m 5172 km/h
14.25 21 3 48832832A45
10451591 kg 5.26.7 m 4768 km/h
13.75 20 3 Enertia 48899000A46
(23003500 lb) (1722 ft) (2942 MPH)
10911682 kg 5.56.7 m 4364 km/h 48898998A46
14.00 19 3 Enertia
(24003700 lb) (1822 ft) (2740 MPH) 48898999A46 (LH)
10911682 kg 5.56.7 m 4364 km/h 48825860A47
(24003700 lb) (1822 ft) (2740 MPH) 48825861A47 (LH)
10911682 kg 5.56.7 m 4364 km/h
13.25 19 5 HighFive 48815758A46
(24003700 lb) (1822 ft) (2740 MPH)
10911682 kg 5.56.7 m 4364 km/h 48825900A48
14.00 19 4 VenSura
(24003700 lb) (1822 ft) (2740 MPH) 48825901A48 (LH)
10911682 kg 5.56.7 m 4364 km/h 4816316A46
(24003700 lb) (1822 ft) (2740 MPH) 4816317A46 (LH)
90-8M0082471 JULY 2014 Page 1A-15


Black Max 8641318 kg 5.56.7 m 4364 km/h
14.50 19 3 48832830A45
11821955 kg 5.57 m 3960 km/h
14.20 18 3 Enertia 48898996A46
(26004300 lb) (1823 ft) (2437 MPH)
12732273 kg 5.87.0 m 3456 km/h 48898994A46
14.50 17 3 Enertia
(28005000 lb) (1923 ft) (2135 MPH) 48898995A46 (LH)
12732273 kg 5.87.0 m 3456 km/h
14.62 17 3 Tempest Plus 488M8026790
(28005000 lb) (1923 ft) (2135 MPH)
12732273 kg 5.87.0 m 3456 km/h
13.50 17 5 HighFive 48821154A46
(28005000 lb) (1923 ft) (2135 MPH)
12732273 kg 5.87.0 m 3456 km/h 48825898A48
14.25 17 4 VenSura
(28005000 lb) (1923 ft) (2135 MPH) 48825899A48 (LH)
12732273 kg 5.87.0 m 3456 km/h 4816314A46
(28005000 lb) (1923 ft) (2135 MPH) 4816315A46 (LH)
Black Max 12732273 kg 5.87.0 m 3456 km/h
15.00 17 3 48832828A45
14092545 kg 6.17.6 m 3151 km/h
14.70 16 3 Enertia 48898992A46
(31005600 lb) (2025 ft) (1932 MPH)
15913045 kg 6.48.2 m 2647 km/h 48898990A46
15.00 15 3 Enertia
(35006700 lb) (2127 ft) (1629 MPH) 48898991A46 (LH)
15913045 kg 6.48.2 m 2647 km/h
15.25 15 3 Black Max 4878116A45
(35006700 lb) (2127 ft) (1629 MPH)
17733545 kg 6.78.5 m 2342 km/h 48898988A46
15.30 14 3 Enertia
(39007800 lb) (2228 ft) (1426 MPH) 488M0079504 (LH)
19554682 kg 1839 km/h 488M0070074
15.60 13 3 Enertia Pontoon
(430010300 lb) (1124 MPH) 488M0070076 (LH)
Black Max 19554682 kg 1839 km/h
16.00 13 3 Pontoon 4878114A45
Aluminum (430010300 lb) (1124 MPH)
16.00 12 3 Pontoon/Work 4816436A45
3182+ kg 129 km/h 488M0070079
16.00 11 3 Enertia Pontoon/Work
(7000+ lb) (118 MPH) 8M0070077 (LH)
Black Max 3182+ kg 129 km/h 4878112A45
16.00 11 3 Pontoon/Work
Aluminum (7000+ lb) (118 MPH) 4878117A40 (LH)
Page 1A-16 90-8M0082471 JULY 2014

Maintenance
1
Section 1B - Maintenance B
Table of Contents
General Specifications....................................................... 1B-2 LowPressure Fuel Filter.............................................1B-8
Outboard Care................................................................... 1B-3 Checking Power Trim Fluid................................................1B-9
Selecting Replacement Parts For Your Outboard...... 1B-3 Checking and Adding Engine Oil....................................... 1B-9
EPA Emissions Regulations.............................................. 1B-3 Changing Engine Oil ....................................................... 1B-10
Emission Certification Label....................................... 1B-3 Engine Oil Capacity.................................................. 1B-10
Owner Responsibility.................................................. 1B-3 Oil Changing Procedure........................................... 1B-10
Inspection and Maintenance Schedule.............................. 1B-3 Changing Oil Filter ................................................... 1B-11
Before Each Use.........................................................1B-3 Oil Filling................................................................... 1B-11
After Each Use............................................................1B-4 Spark Plug Inspection and Replacement.........................1B-12
Every 100 Hours of Use or Once Yearly, Whichever Fuse Replacement...........................................................1B-13
Occurs First.............................................................1B-4 Propeller Replacement.................................................... 1B-14
Every 300 Hours of Use or Three Years.....................1B-4 FloTorq II Propellers................................................ 1B-15
Before Periods of Storage.......................................... 1B-5 FloTorq IV Propellers...............................................1B-15
Corrosion Control Anode................................................... 1B-5 Lubrication Points............................................................ 1B-16
Battery Inspection ............................................................. 1B-5 Gearcase Lubrication.......................................................1B-17
Flushing the Cooling System............................................. 1B-5 Draining Gearcase....................................................1B-17
Top Cowl Removal and Installation................................... 1B-6 Gearcase Lubricant Capacity................................... 1B-18
Removal......................................................................1B-6 Gearcase Lubricant Recommendation..................... 1B-18
Installation...................................................................1B-6 Checking Lubricant Level and Refilling Gearcase.... 1B-18
Flywheel Cover Removal and Installation..........................1B-6 Storage............................................................................ 1B-18
Removal......................................................................1B-6 Storage Preparation..................................................1B-18
Installation...................................................................1B-7 Protecting External Outboard Components.............. 1B-19
Cleaning Care for Top and Bottom Cowls......................... 1B-7 Protecting Internal Engine Components................... 1B-19
Cleaning and Waxing Procedure................................ 1B-7 Gearcase.................................................................. 1B-19
Cleaning Care for the Powerhead (Saltwater Use)............1B-7 Positioning Outboard for Storage............................. 1B-19
Fuel System....................................................................... 1B-7 Battery Storage.........................................................1B-19
Fuel Line Inspection....................................................1B-7 Winter Storage of Batteries.......................................1B-19
Fuel Filters.................................................................. 1B-7
90-8M0082471 JULY 2014 Page 1B-1

Maintenance
General Specifications
Model Specifications
85.8 kW (115 hp)
74.5 kW (100 hp)
Kilowatts (horsepower) 67.1 kW (90 hp)
59.6 kW (80 hp)
55.9 kW (75 hp)
Outboard weight
Standard gearcase models dry weight L 163 kg (359 lb)
Standard gearcase models dry weight XL 172 kg (380 lb)
Command Thrust models L 163 kg (359 lb)
Command Thrust models XL 172 kg (380 lb)
Cylinder bore 90 mm (3.5 in.)
Stroke 81 mm (3.2 in.)
RPM
Idle (in gear) 700 50 RPM
WOT 75/80 45005500 RPM
WOT 90/100/115 50006000 RPM
Fuel system Computer controlled multiport electronic fuel injection
Ignition system SmartCraft engine control module (ECM) digital inductive
Firing order 1342
Charging system 35 A stator with watercooled voltage regulator
Exhaust system Throughthepropeller
Cooling system Watercooled thermostat
Valve opening temperature 46.151.7 C (115125 F)
Operating range 5070 C (122158 F)
Lubrication system
Engine capacity with filter replacement 5.2 L (5.5 US qt)
Trim system
Maximum tilt range 73 (6 to 67)
Maximum trim range 20 (6 to 14)
Lubricant, Sealant, Adhesives

Tube Ref No. Description Where Used Part No.
Propeller shaft
Extreme Grease 8M0071842
Steering cable
81 Anti-Seize Compound Spark plug threads 92-898101385
Page 1B-2 90-8M0082471 JULY 2014

Maintenance

Propeller shaft
95 2-4-C with PTFE Steering cable 92-802859A 1
Battery terminal bolts
Power Trim and Steering
114 Power trim reservoir 92-858074K01
Fluid
119 Storage Seal Rust Inhibitor Spark plug holes 92-858081K03
External metal surfaces of the powerhead and powerhead
120 Corrosion Guard components. 92-802878 55
External metal surfaces
Fuel System Treatment and
124 Fuel tank 92-8M0047932
Stabilizer
Outboard Care
To keep the outboard in the best operating condition, perform the periodic inspections and maintenance listed in the
Inspection and Maintenance Schedule. Proper maintenance will ensure the safety of the operator, passengers, and retain
the outboard dependability.
Record maintenance performed in the Maintenance Log located in the owner's manual. Save all maintenance work orders and
receipts.
Selecting Replacement Parts For Your Outboard

We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants.
EPA Emissions Regulations

All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as
conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is
contingent on certain adjustments set to factory standards. For this reason, the factory procedure for servicing the product must
be strictly followed and, wherever practicable, returned to the original intent of the design. Maintenance, replacement, or
repair of the emission control devices and systems may be performed by any marine spark ignition (SI) engine repair
establishment or individual.
Emission Certification Label

An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the
engine at the time of manufacture.
EMISSION CONTROL
a INFORMATION
f a- Idle speed
THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA
g b- Engine horsepower
b
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE,
SPECIFICATIONS, AND ADJUSTMENTS c- Piston displacement
c IDLE SPEED (in gear): FAMILY:
h d- Engine power kilowatts
hp L HC+NOx:FEL: g/kWh
d e- Date of manufacture
kw CO FEL: g/kWh
i
f- Family number
SPARK PLUG:
GAP:
e LOW PERM/HIGH PERM: j g- Regulated emission limit for the engine family
43210
h- Regulated emission limit for the engine family
i- Recommended spark plug and gap
j- Percent of fuel line permeation
Owner Responsibility
The owner/operator is required to have routine engine maintenance performed to maintain emission levels within prescribed
certification standards.
The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to
exceed their predetermined factory specifications.
Inspection and Maintenance Schedule

Before Each Use
Check the engine oil level. Refer to Checking and Adding Engine Oil.
90-8M0082471 JULY 2014 Page 1B-3

Maintenance
Check that the lanyard stop switch stops the engine.

Inspect the outboard for tightness to the boat transom. If any looseness of the outboard or mounting fasteners exist, tighten
the outboard mounting fasteners to the specified torque. When looking for signs of looseness, look for loss of outboard
transom bracket material or paint caused by movement between the outboard mounting fasteners and the outboard
transom brackets. Also look for signs of movement between the outboard transom brackets and the boat transom (lift plate/
setback bracket).
Description Nm lbin. lbft

Outboard mounting locknuts and bolts standard boat transom 75 55
Outboard mounting locknuts and bolts metal lift plates and setback brackets 122 90
Visually inspect the fuel system for deterioration or leaks.
Check the steering system for binding or loose components.
Check the propeller blades for damage.
After Each Use

Flush out the outboard cooling system if operating in salt or polluted water. Refer to Flushing the Cooling System.
Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in
saltwater.
If operating in saltwater, inspect the powerhead and powerhead components for salt buildup. Refer to Cleaning Care for
the Powerhead (Saltwater Use).
Every 100 Hours of Use or Once Yearly, Whichever Occurs First

Change the engine oil and replace the oil filter. The oil should be changed more often when the engine is operated under
adverse conditions, such as extended trolling. Refer to Changing Engine Oil.
Visually inspect the thermostat for corrosion or a broken spring. Verify the thermostat closes completely at room
temperature. This item should be serviced by an authorized dealer.
Check the lowpressure fuel filter for contaminants. Replace the filter if required. Refer to Fuel System.
Check the outboard mounting fasteners that secure the outboard to the boat transom. Tighten the fasteners to the
specified torque. This item should be serviced by an authorized dealer.

Check the corrosion control anodes. Check more frequently when used in saltwater. Refer to Corrosion Control Anode.
Drain and replace gearcase lubricant. Refer to Gearcase Lubrication.
Inspect the battery. Refer to Battery Inspection.
Saltwater usage: Remove and inspect spark plugs for corrosion and replace spark plugs, as necessary. Apply a thin layer
of AntiSeize Compound only on the threads of the spark plug prior to installation. Refer to Spark Plug Inspection and
Replacement.

Check the wiring and connectors.
Check the tightness of bolts, nuts, and other fasteners.
Check the cowl seals to ensure that the seals are intact and not damaged.
Check the internal cowl sound reduction foam (if equipped) to ensure that the foam is intact and not damaged.
Check that the intake silencer (if equipped) is in place.
Check that the idle relief muffler (if equipped) is in place.
Check for loose hose clamps and rubber boots (if equipped) on the air intake assembly.
Every 300 Hours of Use or Three Years

Replace the water pump impeller (more often if overheating occurs or reduced water pressure is noted). This item should
be serviced by an authorized dealer.
Check the power trim fluid. Refer to Checking Power Trim Fluid.
Page 1B-4 90-8M0082471 JULY 2014

Maintenance
Replace the spark plugs after the first 300 hours or three years. After that, inspect the spark plugs every 300 hours or three
years. Replace spark plugs as needed. Refer to Spark Plug Inspection and Replacement.
Before Periods of Storage

Refer to Storage.
Corrosion Control Anode

The outboard has corrosion control anodes at different locations. An anode helps protect the outboard against galvanic
corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals.
Each anode requires periodic inspection, especially in saltwater which will accelerate the erosion. To maintain this corrosion
protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as
this will reduce effectiveness of the anode.
Two anodes are located on each side of the gearcase. Another anode is installed on the bottom of the transom bracket
assembly.
47569
Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine starting capability.
IMPORTANT: Read the safety and maintenance instructions which accompany your battery.
1. Turn off the engine before servicing the battery.
2. Ensure the battery is secure against movement.
3. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative.
4. Ensure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals.
Flushing the Cooling System

Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will
help prevent a buildup of deposits from clogging the internal water passages.
NOTE: The outboard can be tilted or in the vertical operating position during flushing.
1. With the engine turned off, place the outboard in either the operating position (vertical) or in a tilted position.
2. Remove the flush connector from the bottom cowl.
3. Remove the cover from the flush connector and thread a water hose into the flush connector.
47592
4. Turn on the water tap ( maximum) and let the water flush through the cooling system for about 15 minutes.
5. When flushing is complete, turn off the water and disconnect the water hose.
90-8M0082471 JULY 2014 Page 1B-5

Maintenance
6. Install the cover on the flush connector. Place the flush connector back into the bottom cowl.
Top Cowl Removal and Installation

Removal
Unlock the top cowl by pulling out on the rear cowl latch. Lift the top cowl off the engine.
53762
Installation
1. Lower the top cowl over the engine.
2. Bring the front of the cowl down first and engage the front cowl hook. Lower the cowl into the seated position and apply
pressure to the back of the cowl to lock it in place. Ensure the cowl is securely fastened by trying to pull up on the back of
the cowl.
47633
Flywheel Cover Removal and Installation

Removal
Lift the cover off the four mounting pins.
a - Flywheel cover
b b - Four mounting pins, two on each side of the engine
b
b
53765
Page 1B-6 90-8M0082471 JULY 2014

Maintenance
Installation
Position the cover onto the four mounting pins and secure the cover in place by pushing the cover down onto the mounting
pins.
Cleaning Care for Top and Bottom Cowls

IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches. Always wet the
surface before cleaning. Do not use detergents containing hydrochloric acid. Follow the cleaning and waxing procedure.
Cleaning and Waxing Procedure

1. Before washing, rinse the cowls with clean water to remove dirt and dust that may scratch the surface.
2. Wash the cowls with clean water and a mild nonabrasive soap. Use a soft clean cloth when washing.
3. Dry thoroughly with a soft clean cloth.
4. Wax the surface using a nonabrasive automotive polish (polish designed for clear coat finishes). Remove the applied wax
by hand using a clean soft cloth.
5. To remove minor scratches, use Mercury Marine Cowl Finishing Compound (92859026K 1).
Cleaning Care for the Powerhead (Saltwater Use)

If the outboard is operated in saltwater, remove the top cowl and flywheel cover. Inspect the powerhead and powerhead
components for salt buildup. Wash off any salt buildup from the powerhead and powerhead components with fresh water. Keep
water spray out of the air filter/intake and alternator. After washing, allow the powerhead and components to dry. Apply
Quicksilver or Mercury Precision Lubricants Corrosion Guard spray on the external metal surfaces of the powerhead and
powerhead components. Do not allow the Corrosion Guard spray to come in contact with the alternator drive belt or belt
pulleys.
IMPORTANT: Do not allow lubricant or Corrosion Guard spray to come in contact with the alternator drive belt or the belt
pulleys. The alternator drive belt could slip and be damaged if it becomes coated with any lubricant or Corrosion Guard spray.

External metal surfaces of the powerhead and powerhead
120 Corrosion Guard 92-802878 55
components.
Fuel System
! WARNING
Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot
start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated
and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any
spilled fuel immediately.
IMPORTANT: Use an approved container to collect and store fuel. Wipe up spilled fuel immediately. Material used to contain
spilled fuel must be disposed of in an approved receptacle.
Before servicing any part of the fuel system:
1. Stop engine and disconnect the battery.
2. Perform fuel system service in a wellventilated area.
3. Inspect any completed service work for sign of fuel leakage.
Fuel Line Inspection

Visually inspect the fuel line for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these
conditions are found, the fuel line must be replaced.
Fuel Filters
Refer to the Inspection and Maintenance Schedule for the proper maintenance interval.
90-8M0082471 JULY 2014 Page 1B-7

Maintenance
The engine is equipped with two fuel filters, a lowpressure filter and a highpressure filter. The lowpressure filter can be
serviced as a general maintenance item, however, the highpressure filter should only be serviced by an authorized dealer.
53767
Low pressure fuel filter
LowPressure Fuel Filter

Removal
1. Turn ignition key switch to "OFF" position.
2. Place a rag or towel under the fuel filter to capture fuel that will leak from the hoses and filter.
! WARNING
Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot
start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated
and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any
spilled fuel immediately.
3. Push in on the fuel hose release tabs and disconnect the fuel hoses from the fuel filter.
a a - Fuel hose release tab

b - Lowpressure fuel filter
b
20815
Installation
1. Install the new fuel filter so the arrow points toward the engine.
2. Connect the fuel hoses to the fuel filter securely with the locking hose connections.
3. Visually inspect for fuel leakage from the fuel filter while turning the ignition key to "RUN" position, forcing fuel into the fuel
filter. Repair any fuel leaks found.
Page 1B-8 90-8M0082471 JULY 2014

Maintenance
Checking Power Trim Fluid

1. Tilt the outboard to the full up position and engage the tilt support lever.
a - Tilt support lever

b - Knob
a
b 54169
2. Remove the fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or
Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid
(ATF).

114 Power trim reservoir 92-858074K01
Fluid
47647
Checking and Adding Engine Oil

IMPORTANT: Do not overfill. Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to drain back to
the oil sump. Tilt outboard to vertical (not tilted) position when checking engine oil. For accurate readings, check oil only when
engine is cold or after engine has not run for at least an hour.
1. Before starting (cold engine) tilt outboard out/up past vertical to allow trapped oil to drain back to the oil sump. Allow
outboard to remain tilted for approximately one minute.
2. Tilt outboard to vertical operating position.
3. Remove the top cowl. Refer to Maintenance Top Cowl Removal and Installation.
4. Pull out the dipstick. Wipe the dipstick end with a clean rag or towel and push it back in all the way.
5. Pull the dipstick back out again and observe the oil level. Oil should be in the operating range (cross hatched region).
90-8M0082471 JULY 2014 Page 1B-9

Maintenance
IMPORTANT: Do not try to fill the oil level to the top of the operating range (cross hatched region). Oil level is correct as
long as it appears in the operating range (cross hatched region).
b a- Oil level operating range

b- Top bar
c- Bottom bar
d d- Upper 1/3 level
c
53753
6. If the oil level is below the operating range (cross hatched region), remove the oil filler cap and add approximately 500 ml
(16 oz) of the specified outboard motor oil. Allow a few minutes for the added oil to drain to the oil sump and check the
level on the dipstick. Repeat the process until the oil level is on the operating range (cross hatched region). Do not try to fill
to the upper end of the operating range (cross hatched region).
53755
IMPORTANT: Inspect oil for signs of contamination. Oil contaminated with water will have a milky color to it; oil
contaminated with fuel will have a strong fuel smell. If contaminated oil is noticed, have the engine checked by your dealer.
7. Push the dipstick back in all the way.
8. Install the oil fill cap handtight.
9. Install the top cowl.
Changing Engine Oil

Engine Oil Capacity
Engine oil capacity is approximately 5.2 liter (5.5 US qt).
Oil Changing Procedure

1. Tilt the outboard out/up past vertical for approximately one minute to allow any trapped oil to drain back to the oil sump.
2. Tilt the outboard to a vertical position.
3. Use a 16 mm (5/8 in.) wrench and loosen the oil drain valve so that it can be turned by hand. Be careful not to open the
valve too far allowing oil to drain.
4. Attach a 12 mm (7/16 in.) I.D. drain hose to the oil drain valve. Position the opposite end of the hose into an appropriate
container.
5. Loosen the oil drain valve 21/2 turns to allow oil to drain. Do not exceed 21/2 turns.
IMPORTANT: Do not loosen the oil drain valve more than 21/2 turns out. The oil seal could get damaged beyond 21/2
turns.
6. After the oil has drained, handtighten the oil drain valve (clockwise) and remove the oil drain hose.
7. Tighten the oil drain valve to the specified torque. Clean up any oil in the valve area.
Page 1B-10 90-8M0082471 JULY 2014

Maintenance

Oil drain valve 15 133
IMPORTANT: Overtightening the oil drain valve can damage the oil sump.
a a - Oil drain valve

b - Drain hose
c - Loosen 21/2 turns maximum
2-12
b
c
48870
Changing Oil Filter

1. Remove the plug from the oil trough and attach a 12 mm (7/16 in.) I.D. drain hose to the fitting. Position the opposite end of
the hose into an appropriate container.
2. Unscrew the old filter by turning the filter to the left.
3. Allow oil in the trough to drain and remove the oil drain hose.
4. Clean any oil from the oil trough and install the plug.
5. Clean the oil filter mounting base. Apply a film of clean oil to the filter gasket. Do not use grease. Screw new filter on until
gasket contacts base, then tighten 3/4 to 1 turn.
a- Loosen
b- Oil filter
a c- Oil trough
b d- Drain hose
c
d
53792
Oil Filling
1. Remove the oil fill cap and add approximately 5.2 liter (5.5 US qt) of the recommended oil. This will bring the oil level within
the midpoint of the operating range.
2. Idle engine for five minutes and check for leaks. Stop the engine. For an accurate oil level reading, allow the engine to cool
for at least an hour before checking the oil level. Refer to Fuel and Oil Checking and Adding Engine Oil.
90-8M0082471 JULY 2014 Page 1B-11

Maintenance
NOTE: Checking the oil level within five minutes of engine shutdown can falsely read up to 1 liter (1 US qt) low. Allow the
engine to cool for at least an hour before checking the oil level.
53755
Spark Plug Inspection and Replacement

1. Remove the spark plug leads. Pull the rubber boots off the spark plugs.
53781
2. Remove the spark plugs to inspect.
53782
3. Replace the spark plug if the electrode is worn; the insulator is rough, cracked, broken, or blistered; or if the precious metal
is not visible on the spark plug electrode.
Page 1B-12 90-8M0082471 JULY 2014

Maintenance
IMPORTANT: The color of the plug may not accurately reflect its condition. To accurately diagnose a faulty plug, inspect
the precious metal on the plug's electrode. If no precious metal is visible, replace the plug.
a - Precious metal
9381
4. Set the spark plug gap. Refer to General Specifications.
27848
a. All of the spark plugs should have the gap checked and corrected as necessary before installation.
b. Measure the gap with a feeler gauge or pin gauge. Never use a wedgetype gap checking tool to inspect or to adjust
the gap.
c. If an adjustment is necessary, do not pry or apply any force on the center electrode. This is critical with any type of
spark plug that has a wear surface, such as platinum or iridium added to either the ground electrode or the center
electrode.
d. When it is necessary to widen the gap, use a tool that only pulls back on the ground electrode without touching the
center electrode, the porcelain, or the wear portion of the ground electrode.
e. When it is necessary to close the gap, gently tap the plug ground electrode on a hard surface.
5. Saltwater use Apply a thin coating of AntiSeize Compound only on threads of spark plugs.

6. Before installing spark plugs, clean off any dirt on the spark plug seats. Install the plugs fingertight and then tighten an
additional 1/4 turn or tighten to the specified torque.

Spark plug 27 20
Fuse Replacement
IMPORTANT: Always carry spare fuses.
The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring. If a fuse is blown, try to locate
and correct the cause of the overload. If the cause is not found, the fuse may blow again.
90-8M0082471 JULY 2014 Page 1B-13

Maintenance
Open the fuse holder and look at the silver colored band inside the fuse. If the band is broken, replace the fuse. Replace fuse
with a new fuse with the same rating.
a - Cover
b - Spare fuse holders
a c - Fuse 3 HELM 15 amp 14 pin remote control harness/
cowl trim switch
d - Fuse 4 IGN. 20 amp ignition system
e - Fuse 2 FUEL 20 amp fuel delivery
f - Fuse 1 DIAG. 2 amp diagnostics/vessel (accessory)
harness
g - Good fuse
h - Blown fuse
b
g
f c
2 15
h 20 20
e d
53784
Propeller Replacement
! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the
engine from starting. Place a block of wood between the propeller blade and the antiventilation plate.
1. Shift outboard to the neutral (N) position.
26838
2. Straighten the bent tabs on the propeller nut retainer.

3. Place a block of wood between the gearcase and the propeller to hold the propeller and remove the propeller nut.
26901
Page 1B-14 90-8M0082471 JULY 2014

Maintenance
4. Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller
removed by an authorized dealer.
5. Coat the propeller shaft with Extreme Grease or 24C with PTFE.
47623

Extreme Grease Propeller shaft 8M0071842
95 2-4-C with PTFE Propeller shaft 92-802859A 1
IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft, especially in saltwater, always
apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and
also each time the propeller is removed.
FloTorq II Propellers
1. Install the propeller onto the shaft with the supplied components as shown.
2. Place the locknut retainer over the raised pins on the drive sleeve adapter and tighten the locknut to the specified torque.
3. Secure the locknut by bending the tabs up against the locknuts.
c
a a- Forward thrust washer
b h b- Drive sleeve
d e g
c- Propeller
d- Drive sleeve adapter
e- Locknut retainer
f- Locknut
g- Raised pins
f 45232 h- Tabs bent against the locknut

Propeller nut 75 55
FloTorq IV Propellers
1. Install the propeller onto the shaft with the supplied components as shown.
2. Tighten the locknut to the specified torque.
3. Secure the locknut by bending three of the tabs into the grooves in the drive sleeve adapter.
c
a- Forward thrust washer
a b b- Drive sleeve
d e g
c- Propeller
d- Drive sleeve adapter
e- Locknut retainer
f- Locknut
g- Tabs bent into grooves
f 45248
90-8M0082471 JULY 2014 Page 1B-15

Maintenance

Propeller nut 75 55
Lubrication Points
1. Lubricate the following with Extreme Grease or 24C with PTFE.

Extreme Grease Propeller shaft 8M0071842
95 2-4-C with PTFE Propeller shaft 92-802859A 1
Propeller shaft Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire
propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft.
47623
2. Lubricate the following with 24C with PTFE or Extreme Grease.

95 2-4-C with PTFE Steering cable 92-802859A 1
Extreme Grease Steering cable 8M0071842
Steering cable grease fitting (if equipped) Rotate steering wheel to fully retract the steering cable end into the
outboard tilt tube. Lubricate through fitting.
a b a - Fitting
b - Steering cable end
47651
! WARNING
Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely
retract the end of the steering cable before applying lubricant.
Page 1B-16 90-8M0082471 JULY 2014

Maintenance
Tilt lever grease fitting and the swivel pin grease fitting.
a - Tilt lever grease fitting

b - Swivel pin grease fitting
54186
3. Lubricate the following with lightweight oil.

Steering link rod pivot points Lubricate pivot points.
47652
Gearcase Lubrication
When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant. If water is present, it may
have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored
appearance. If water is noticed, have the gearcase checked by your dealer. Water in the lubricant may result in premature
bearing failure or, in freezing temperatures, will turn to ice and damage the gearcase.
Examine the drained gearcase lubricant for metal particles. A small amount of metal particles indicates normal gear wear. An
excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an
authorized dealer.
Draining Gearcase
1. Place the outboard in a vertical operating position.
2. Remove the propeller. Refer to Propeller Replacement.
3. Place the drain pan below the outboard.
4. Remove the vent plug and fill/drain plug and drain lubricant.
a - Vent plug
b - Fill/drain plug
b
a
22692
90-8M0082471 JULY 2014 Page 1B-17

Maintenance
Gearcase Lubricant Capacity

Gearcase Lubricant Capacity (approximate)
Standard 800 ml (27.1 fl oz)
Command Thrust (righthand and lefthand rotation) 760 ml (25.7 fl oz)
Gearcase Lubricant Recommendation

Mercury or Quicksilver High Performance Gear Lubricant.
Checking Lubricant Level and Refilling Gearcase

1. Place the outboard in a vertical operating position.
2. Remove the vent plug/sealing washer.
3. Remove the fill/drain plug. Place the lubricant tube into the fill hole and add the lubricant until it appears at the vent hole.
a - Vent hole
b - Fill hole
a
22693
IMPORTANT: Replace the sealing washers if damaged.

4. Stop adding the lubricant. Install the vent plug and sealing washer before removing the lubricant tube.
5. Remove the lubricant tube and install cleaned fill/drain plug and sealing washer.
Storage
Storage Preparation
The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by
freezing of trapped water.
The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage
(two months or longer).
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
Fuel System
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage
the fuel system. If the gasoline being used contains alcohol, it is advisable to drain as much of the remaining gasoline as
possible from the fuel tank, remote fuel line, and engine fuel system.
IMPORTANT: This outboard is equipped with a closed fuel system when the engine is not running. With this closed system,
fuel within the engine's fuel system, other than the fuel tank, will remain stable during normal storage periods without the
addition of fuel treatment stabilizers.
Fill the fuel tank and engine fuel system with treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed
with the following instructions.
Portable fuel tank Pour the required amount of Fuel System Treatment and Stabilizer (follow instructions on container)
into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel.
Permanently installed fuel tank Pour the required amount of Fuel System Treatment and Stabilizer (follow instructions on
container) into a separate container and mix with approximately one liter (one quart) of gasoline. Pour this mixture into fuel
tank.
Page 1B-18 90-8M0082471 JULY 2014

Maintenance

Fuel System Treatment
124 Fuel tank 92-8M0047932
and Stabilizer
Protecting External Outboard Components

Touch up any paint nicks. See your dealer for touchup paint.
Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control
anodes).

120 Corrosion Guard External metal surfaces 92-802878 55
Protecting Internal Engine Components

IMPORTANT: Refer to Maintenance Spark Plug Inspection and Replacement for correct procedure for removing spark plugs.
Remove pencil coils and spark plugs.
Spray approximately 30 ml (1 fl oz) of Storage Seal Rust Inhibitor into each spark plug hole.

Storage Seal Rust
119 Spark plug holes 92-858081K03
Inhibitor
Actuate key/push button start switch to crank the engine through one start cycle, which will distribute the storage seal
throughout the cylinders.
Install spark plugs and pencil coils.
Gearcase
Drain and refill the gearcase lubricant (refer to Gearcase Lubrication).
Positioning Outboard for Storage

Store outboard in an upright (vertical) position to allow water to drain out of the outboard.
NOTICE
Storing the outboard in a tilted position can damage the outboard. Water trapped in the cooling passages or rain water
collected in the propeller exhaust outlet in the gearcase can freeze. Store the outboard in the full down position.
Battery Storage
Follow the battery manufacturer's instructions for storage and charging.
Remove the battery from the boat and check water level. Charge if necessary.
Store the battery in a cool, dry place.
Periodically check the water level and charge the battery during storage.
Winter Storage of Batteries

Battery companies are not responsible for battery damage, either in winter storage or in dealer stock, if the following
instructions are not observed:
1. Remove battery from its installation as soon as possible and remove all grease, sulfate, and dirt from the top surface by
running water over top of the battery. Be sure, however, the vent caps are tight beforehand and blow off all excess water
thoroughly with compressed air. Check water level, making sure the plates are covered.
2. When adding distilled water to the battery, be extremely careful not to fill more than 4.8 mm (3/16 in.) above perforated
baffles inside the battery. Battery solution or electrolyte expands from heat caused by charging. Overfilling the battery will
cause the electrolyte to overflow (if filled beyond 4.8 mm [3/16 in.] above baffles).
3. Grease terminal bolts with 24C with PTFE and store the battery in a cooldry place. Remove the battery from storage
every 3045 days, check the water level, and put on charge for 5 or 6 amps. Do not fast charge.

95 2-4-C with PTFE Battery terminal bolts 92-802859A 1
90-8M0082471 JULY 2014 Page 1B-19

Maintenance
4. If specific gravity drops below 1.240, check battery for reason and recharge. When gravity reaches 1.260, discontinue
charging. To check specific gravity, use a hydrometer, which can be purchased locally.
5. Repeat preceding charging procedure every 3045 days, as long as the battery is in storage, for best possible
maintenance during inactive periods to ensure a good serviceable battery in spring. When ready to place the battery back
in service, remove excess grease from the terminals (a small amount is desirable on terminals at all times), recharge
again, as necessary, and reinstall the battery.
Page 1B-20 90-8M0082471 JULY 2014

General Information
1
Section 1C - General Information C
Table of Contents
Serial Number Location..................................................... 1C-2 Power Trim and Tilt..........................................................1C-12
Powerhead Views.............................................................. 1C-3 Power Trim And Tilt.................................................. 1C-12
Powerhead Front View............................................... 1C-3 Power Trim Operation.............................................. 1C-12
Powerhead Starboard View........................................1C-4 Tilting Operation....................................................... 1C-13
Aft View...................................................................... 1C-5 Manual Tilting........................................................... 1C-13
Port View.................................................................... 1C-6 Auxiliary Tilt Switch...................................................1C-13
Top View.....................................................................1C-7 Shallow Water Operation..........................................1C-13
Conditions Affecting Performance..................................... 1C-7 Compression Check........................................................ 1C-14
Weather...................................................................... 1C-7 Cylinder Leakage Testing................................................ 1C-14
Weight Distribution (Passengers and Gear) Inside the Analysis.................................................................... 1C-15
Boat.........................................................................1C-8 Painting Procedures........................................................ 1C-15
Bottom of Boat ...........................................................1C-8 Propellers................................................................. 1C-15
Water Absorption........................................................1C-8 Gear Housing........................................................... 1C-15
Cavitation....................................................................1C-8 Decal Removal................................................................ 1C-16
Ventilation...................................................................1C-8 Decal Application............................................................. 1C-16
Detonation.................................................................. 1C-8 Application Tips........................................................ 1C-16
Following Complete Engine Submersion ..........................1C-9 Applying the Decal....................................................1C-16
Engine Submerged While Running (Special Entrapped Air Removal............................................ 1C-17
Instructions)............................................................ 1C-9 Final Decal Squeegee.............................................. 1C-17
Freshwater Submersion (Special Instructions)...........1C-9 Cleaning and Maintenance.............................................. 1C-17
Saltwater Submersion (Special Instructions)..............1C-9 General Cleaning Instruction.................................... 1C-17
Fuel and Oil....................................................................... 1C-9 Shipping of Hazardous Material (HazMat) and Engine/
Fuel Recommendations..............................................1C-9 Components Containing Hazardous Material.............. 1C-18
Filling Fuel Tank....................................................... 1C-10 Outboard Service Bulletin 200807...........................1C-18
Engine Oil Recommendations.................................. 1C-10 Overview of Regulations...........................................1C-18
Warning System.............................................................. 1C-11 Overview of Training Requirements......................... 1C-18
Warning Horn Signals...............................................1C-11 Shipping of Complete Engines and Major Assemblies
Engine Guardian System..........................................1C-11 .............................................................................. 1C-18
SmartCraft Product...................................................1C-12 More Information on Hazardous Material................. 1C-18
90-8M0082471 JULY 2014 Page 1C-1

General Information
Special Tools
Compression Tester with Adapter SnapOn EEPV303B
Checks cylinder compression. Use with M14 x 1.25 adapter.
8511
Cylinder Leakage Tester SnapOn EEPV309A
Aids in checking cylinder leakdown.
11604
Serial Number Location

The serial number is located on the starboard side of the swivel bracket.
b
Serial Number
a xxxxxxxx a- Serial number

xxxx
xxxxxxxx b- Model year
Max RPM XXX c- Model designation
HPXX KW XX c
LBXX KG XX d- Year manufactured
Mercury Marine
Brunswick Corp
e- Certified Europe Insignia (as applicable)
Fond du Lac, Wi 52935
Assembled in the USA
from US and foreign
components
e xx d
21552
Page 1C-2 90-8M0082471 JULY 2014

General Information
Powerhead Views
Powerhead Front View
15 1- Power stud
14 2- CAN terminator resistor
3- Engine harness connector
4- Engine control module (ECM)
13 5- Power trim cowl switch connector
6- Steering link rod
7- Battery cables
12
8- Trim position sensor and power trim
harnesses
11
9- 14pin engine harness connector
10 10 - Main power relay
1 11 - Power trim wire bullet connectors
9 12 - Fuse holder
13 - Start relay
2 14 - Trim up power trim motor relay
15 - Trim down power trim motor relay
8
3
7
4
6
5
54862
90-8M0082471 JULY 2014 Page 1C-3

General Information
Powerhead Starboard View
26 27 1- Flywheel
2- Starter solenoid
3- Starter motor
1 4- Engine ground and
negative cables
5- Idle air control (IAC)
2
6- Oil filter
3 7- Fuel line
8- Trim position sensor
25 and power trim
4 harnesses
9- Starboard transom
24 5 bracket
10 - Lower mount
23 11 - Pitot tube
6
12 - Fuel supply module
22 fuel cooler water dump
7 hose
21 13 - Oil drain valve
14 - Driveshaft housing
20 15 - Fuel supply module
19 fuel supply hose
16 - Water pump indicator
tube
17 - Adapter plate
18 18 - Upper mount
19 - Timing chain tensioner
17 8 cover
16 20 - Throttle lever
21 - Lowpressure fuel filter
15
9 22 - Fuel rail
14 23 - Air intake manifold
24 - Oil dipstick
13 25 - Manifold air
temperature (MAT)
sensor
26 - Throttle body screen
12
10 27 - Throttle position
sensor (TPS)
11
54863
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General Information
Aft View
1 1- Thermostat hose
2- Water pump indicator hose
15 2
3- Crankcase ventilation hose
3 4- Fuel rail
5- Fuel injector #1
14 4 6- Fuel injector #2
7- Fuel injector #3
13 5
8- Fuel injector #4
9- Fuel pump connector
10 - Idle relief muffler grommet
11 - Fuel supply module (FSM)
6
12 - Idle relief muffler
13 - Spark plug wire
14 - Camshaft cover
15 - Oil fill cap
7
9
12
10
11 54864
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General Information
Port View
1- Fuse holder
2- Exhaust manifold
1
3- Spark plug #1
4- Voltage regulator
2 5- Spark plug #2
15 6- Spark plug #3
3 7- Spark plug #4
8- Water strainer to block
4 hose
9- Water strainer to FSM
14 5 hose
10 - Water strainer
11 - Digital speedometer
connector (optional)
6 12 - Flush hose fitting
13 13 - Ignition coil (2 and 3)
14 - Ignition coil (1 and 4)
15 - Voltage regulator/stator
7 wire connector
12 9
11
10
54865
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General Information
Top View
1 1- Oil fill cap

9 2- Water pump indicator outlet fitting
2
3- Water pressure sensor (optional)
4- Crankshaft position sensor (CPS)
3
5- Flywheel
6- Starter
8 7- Throttle body screen
8- Water temperature sensor
9- Thermostat housing
4
7
5
54866
Conditions Affecting Performance

Weather
It is a known fact that weather conditions exert a profound effect on the power output of internal combustion engines.
Established horsepower ratings refer to the power the engine will produce at its rated RPM under a specific combination of
weather conditions.
Corporations internationally have settled on adoption of International Standards Organization (ISO) engine test standards, as
set forth in ISO 3046 standardizing the computation of horsepower from data obtained on the dynamometer. All values are
corrected to the power the engine will produce at sea level, at 30% relative humidity, at 25 C (77 F) temperature, and a
barometric pressure of 29.61 inches of mercury.
Summer conditions of high temperature, low barometric pressure, and high humidity all combine to reduce the engine power.
This, in turn, is reflected in decreased boat speeds as much as 3 to 5 km/h (2 to 3 MPH) in some cases. Nothing will regain this
speed for the boater but cooler, dry weather.
Pointing out the consequences of weather effects, an engine running on a hot, humid day may encounter a loss of as much as
14% of the horsepower it would produce on a dry, brisk day. The horsepower that any internal combustion engine produces,
depends upon the density of the air that it consumes. The density of air is dependent upon the ambient air temperature, the
barometric pressure, and the humidity (water vapor) content.
Accompanying the effects of weather inspired loss of power is a second, but more subtle loss. Consider a boat rigged during
cooler, less humid weather with a propeller that allowed the engine to turn within its recommended RPM range at full throttle.
Higher temperatures with high humidity weather will consequently decrease the available horsepower. The propeller, in effect,
is too large for the atmospheric conditions and the engine operates at less than its recommended RPM.
The enginerated horsepower is a direct relation to the engine's RPM. An engine with too large of a propeller will have a further
loss of horsepower and subsequent decrease in boat speed. This secondary loss of RPM and boat speed can be regained by
switching to a smaller pitch propeller that allows the engine to run at recommended RPM.
For boaters to realize optimum engine performance under changing weather conditions, it is essential the engine has the
proper propeller to allow it to operate at, or near, the top end of the recommended maximum RPM range at wideopen throttle
with a normal boat load. Not only does this allow the engine to develop full power, but equally important, the engine will be
operating in an RPM range that discourages damaging detonation. This enhances overall reliability and durability of the engine.
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General Information
Weight Distribution (Passengers and Gear) Inside the Boat

Shifting weight to rear (stern):
Generally increases speed and engine RPM
Causes bow to bounce in choppy water
Increases danger of following wave splashing into the boat when coming off plane
At extremes, can cause the boat to porpoise
Shifting weight to front (bow):
Improves ease of planing
Improves rough water ride
At extremes, can cause the boat to veer back and forth (bow steer)
Bottom of Boat
For maximum speed, a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and
smooth in fore and aft direction.
Hook: Exists when bottom is concave in fore and aft direction when viewed from the side. When boat is planing, hook
causes more lift on bottom near transom and allows bow to drop, thus greatly increasing wetted surface and reducing boat
speed. Hook frequently is caused by supporting boat too far ahead of transom while hauling on a trailer or during storage.
Rocker: The reverse of hook and much less common. Rocker exists if bottom is convex in fore and aft direction when
viewed from the side, and boat has strong tendency to porpoise.
Surface roughness: Moss, barnacles, etc., on boat or corrosion of outboard's gear housing increase skin friction and
cause speed loss. Clean surfaces when necessary.
Water Absorption
It is imperative that all throughthehull 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.
Cavitation
Cavitation occurs when water flow cannot follow the contour of a fastmoving underwater object, such as a gear housing or a
propeller. Cavitation increases propeller speed while reducing boat speed. Cavitation can seriously erode the surface of the
gear housing or the propeller. Common causes of cavitation are:
Weeds or other debris snagged on the propeller
Bent propeller blade
Raised burrs or sharp edges on the propeller
Ventilation
Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speedup
and a reduction in boat speed. Air bubbles strike the propeller blade and cause erosion of the blade surface. If allowed to
continue, eventual blade failure (breakage) will occur. Excessive ventilation is usually caused by:
Drive unit trimmed out too far
A missing propeller diffuser ring
A damaged propeller or gear housing, which allows exhaust gases to escape between propeller and gear housing
Drive unit installed too high on transom
Detonation
Detonation in a 4cycle engine resembles the pinging heard in an automobile engine. It can be otherwise described as a tinlike
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 4cycle application are as follows:
Overadvanced ignition timing
Use of low octane gasoline
Propeller pitch too high: engine RPM below recommended maximum range
Lean fuel mixture at, or near, wideopen throttle
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Spark plugs: heat range too hot, incorrect reach, crossfiring
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
Following Complete Engine Submersion

Engine Submerged While Running (Special Instructions)
When an engine is submerged while running, the possibility of internal engine damage is greatly increased. After the engine is
recovered, remove the spark plugs. If the engine fails to turn over freely when turning the flywheel, the possibility of internal
damage (bent connecting rod and/or bent crankshaft) exists. The powerhead must be disassembled for inspection.
Freshwater Submersion (Special Instructions)

1. Recover the engine as quickly as possible.
2. Place the engine at full trim in.
3. Remove the cowling.
4. Flush the exterior of the outboard with fresh water to remove mud, weeds, etc. Do not attempt to start the engine if sand
has entered the powerhead. Disassemble the powerhead if necessary to clean the components.
5. Remove the spark plugs and get as much water as possible out of the powerhead. Most of the water inside the combustion
chambers can be eliminated by rotating the flywheel while the engine is trimmed all the way in.
6. Remove the integrated air fuel module (IAFM) and drain the water from the IAFM assembly.
7. Remove and clean the fuel rail, fuel supply module, idle air control, throttle body, and fuel pump assembly.
8. Pour approximately one teaspoon of engine oil into each spark plug opening. Rotate the flywheel to distribute the oil in the
cylinders.
9. Change the engine oil. Run the outboard for a short time and check for the presence of water in the oil. If water is present,
the oil will appear milky. Drain and replace the oil.
10. Dry all wiring and electrical components using compressed air.
11. Disassemble the engine starter motor and dry all the internal parts with compressed air. Be careful not to lose the brush
springs.
12. Reinstall the spark plugs.
13. Attempt to start the engine, using a fresh fuel source. If the engine starts, it should be run for at least one hour to eliminate
any water in the engine. If water is present, the oil will appear milky. Drain and replace the oil as previously mentioned.
NOTE: The fuel system is closed to ambient air at all times when the engine is not running.
14. If the engine fails to start, determine if the cause is fuel related, electrical, or mechanical. The engine should be run within
two hours after recovery from the water, or serious internal damage will occur. If the engine is unable to start within two
hours of recovery, disassemble the engine and clean all parts. Apply oil as soon as possible.
Saltwater Submersion (Special Instructions)

Due to the corrosive effect of saltwater on internal engine components, complete disassembly of the engine is necessary
before any attempt is made to start the engine.
Fuel and Oil

Fuel Recommendations
IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper
gasoline is considered misuse of the engine, and damage caused thereby will not be covered under the limited
warranty.
Fuel Ratings
Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following
specifications:
USA and Canada having a posted pump octane rating of 87 (R+M)/2 minimum. Premium gasoline (92 [R+M]/2 octane) is
also acceptable. Do not use leaded gasoline.
Outside USA and Canada having a posted pump octane rating of 90 RON minimum. Premium gasoline (98 RON) is also
acceptable. If unleaded gasoline is not available, use a major brand of leaded gasoline.
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General Information
Using Reformulated (Oxygenated) Gasolines (USA Only)

This type of gasoline is required in certain areas of the USA. The two types of oxygenates used in these fuels are alcohol
(ethanol) or ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasolines
Containing Alcohol.
These reformulated gasolines are acceptable for use in your Mercury Marine engine.
Gasolines Containing Alcohol

If the gasoline in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), you should be aware of certain
adverse effects that can occur. These adverse effects are more severe with methanol. Increasing the percentage of alcohol in
the fuel can also worsen these adverse effects.
Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air, resulting in a
separation of the water/alcohol from the gasoline in the fuel tank.
The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do
not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations
on the boat's fuel system components (fuel tanks, fuel lines, and fittings). Be aware that gasolines containing alcohol may
cause increased:
Corrosion of metal parts
Deterioration of rubber or plastic parts
Fuel permeation through rubber fuel lines
Starting and operating difficulties
! WARNING
Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system
components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or
deterioration requires replacement before further engine operation.
Because of possible adverse effects of alcohol in gasoline, it is recommended that only alcoholfree gasoline be used where
possible. If only fuel containing alcohol is available, or if the presence of alcohol is unknown, increased inspection frequency for
leaks and abnormalities is required.
IMPORTANT: When operating a Mercury Marine engine on gasoline containing alcohol, storage of gasoline in the fuel tank for
long periods should be avoided. Long periods of storage, common to boats, create unique problems. In cars, alcoholblend
fuels normally are consumed before they can absorb enough moisture to cause trouble, but boats often sit idle long enough for
phase separation to take place. In addition, internal corrosion may take place during storage if alcohol has washed protective
oil films from internal components.
Filling Fuel Tank

! WARNING
Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. Always stop the engine and
do not smoke or allow open flames or sparks in the area while filling fuel tanks.
Fill the fuel tanks outdoors away from heat, sparks, and open flames.
Remove the portable fuel tanks from the boat to fill them.
Always stop the engine before filling the tanks.
Do not completely fill the fuel tanks. Leave approximately 10% of the tank volume unfilled. Fuel will expand in volume as its
temperature rises and can leak under pressure if the tank is completely filled.
Portable Fuel Tank Placement in the Boat

Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions.
Engine Oil Recommendations

Mercury or Quicksilver NMMA FCW certified SAE 10W30 4Stroke Marine Engine Oil is recommended for general,
alltemperature use. As optional choices, Mercury or Quicksilver NMMA FCW SAE 25W40 Mineral Marine 4Stroke Engine
Oil or SAE 25W40 Synthetic Blend Marine 4Stroke Engine Oil may be used. If the recommended Mercury or Quicksilver
NMMA FCW certified oils are not available, a major outboard manufacturers brand of NMMA FCW certified 4Stroke outboard
oil of similar viscosity may be used.
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IMPORTANT: The use of nondetergent oils, multiviscosity oils (other than Mercury or Quicksilver NMMA FCW certified oil or a
major brand NMMA FCW certified oil), low quality oils, or oils that contain solid additives are not recommended.
2 5
54715
Warning System
Warning Horn Signals
When the key switch is turned to the ON position, the horn will turn on for a moment as a test to indicate the horn is working.
The warning horn will emit either a continuous beep or short intermittent beeps. This will alert the operator and help identify the
following listed situations. For visual display of the specific engine functions and for additional engine data, refer to SmartCraft
Product information, following.
Warning Horn
Function Sound Description
Start up Single beep Normal system test.
Low battery Four beeps Battery charging unable to keep up with demand. Raise the engine speed to
every 2 minutes increase charge, or shut down accessories to reduce the demand.
Cooling system Continuous The Engine Guardian System is activated. Power limit will vary with the level of
problem overheat. Shift the outboard into neutral and check for a steady stream of water
coming out of the water pump indicator hole. If no water is coming out of the water
pump indicator hole, or flow is intermittent, stop the engine and check the water
intake holes for obstruction.
Oil pressure low Continuous The Engine Guardian System is activated. Power limit will vary depending on the
available oil pressure. Stop the engine and check the oil dipstick. Add oil if
necessary. Refer to Section 1B Checking and Adding Engine Oil.
Engine overspeed Continuous The warning horn is activated any time the engine speed exceeds the maximum
allowable RPM. The system will limit the engine speed to within the allowable range.
Engine overspeed indicates a condition that should be corrected. Overspeed could
be caused by incorrect propeller pitch, engine height, trim angle, tilt angle (shallow
water operation) etc.
Single beep May be a problem with one of the engine functions.
Sensor/Actuator (engine running)
out of range Continuous The Engine Guardian System is activated. Power limit will restrict the engine speed
to either idle or 55%, depending on the fault.
Engine Guardian System

The Engine Guardian System monitors the critical sensors on the engine for any early indications of problems. The system will
respond to a problem by emitting a continuous beep and/or reducing engine power in order to provide engine protection.
If Guardian System has been activated, reduce throttle speed. The problem will need to be identified and corrected, if possible.
The system must be reset before the engine will operate at higher speeds. Moving the throttle lever back to the idle position will
reset the system.
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SmartCraft Product
A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument
package will display are engine RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel consumption, and
engine operating hours.
The SmartCraft instrument package will also aid in Engine Guardian diagnostics. The SmartCraft Instrument package will
display critical engine alarm data and potential problems.
Power Trim and Tilt

The outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by
pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down. Moving the outboard
further away from the boat transom is called trimming out or up. The term trim generally refers to the adjustment of the
outboard within the first 20 range of travel. This is the range used while operating the boat on plane. The term tilt is generally
used when referring to adjusting the outboard further up out of the water. With the engine turned off and ignition switch turned
on, the outboard can be tilted out of the water. At low idle speed, the outboard can also be tilted up past the trim range to
permit, for example, shallow water operation.
a - Trim switch
b - Tilt range
c - Trim range
a
b 20760
Power Trim Operation

With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of
the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an
improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some
potential control hazards.
The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque
results from the outboard being trimmed so the propeller shaft is not parallel to the water surface.
! WARNING
Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss
of boat control. Maintain control of the boat if trimming beyond a neutral steering condition.
Consider the following lists carefully.

1. Trimming in or down can:
Lower the bow.
Result in quicker planing off, especially with a heavy load or a stern heavy boat.
Generally improve the ride in choppy water.
Increase steering torque or pull to the right (with the normal righthand rotation propeller.)
In excess, can lower the bow of some boats to a point where they begin to plow with their bow in the water while on
plane. This can result in an unexpected turn in either direction (called bow steering or oversteering) if any turn is
attempted, or if a significant wave is encountered.
! WARNING
Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the
operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the
boat in a safe manner.
In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by purchasing a stainless
steel tilt pin from your dealer and inserting it in whatever adjustment hole in the transom brackets is desired. The
nonstainless steel shipping bolt should not be used in this application other than on a temporary basis.
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2. Trimming out or up can:
Lift the bow higher out of the water.
Generally increase top speed.
Increase clearance over submerged objects or a shallow bottom.
Increase steering torque or pull to the left at a normal installation height (with the normal righthand rotation propeller.)
In excess, can cause boat porpoising (bouncing) or propeller ventilation.
Cause engine overheating if any cooling water intake holes are above the waterline.
Tilting Operation
To tilt the outboard, shut off the engine and press the trim/tilt switch or auxiliary tilt switch to the up position. The outboard will
tilt up until the switch is released or it reaches its maximum tilt position.
1. Engage the tilt support lever by rotating the knob to bring the support lever upward.
2. Lower the outboard to rest on the tilt support lever.
3. Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever down. Lower the
outboard.
a - Tilt support lever

b - Knob
a
b
27778
Manual Tilting
If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.
NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up
during reverse operation.
Turn out the manual tilt release valve three turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard
to the desired position and tighten the manual tilt release valve.
22362
Auxiliary Tilt Switch

This switch can be used to tilt the outboard up or down using the power trim system.
a - Auxiliary tilt switch
20886
Shallow Water Operation

When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom.
1. Reduce the engine speed below 2000 RPM.
2. Tilt the outboard up. Make sure all the water intake holes stay submerged at all times.
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3. Operate the engine at slow speed only. If engine speed exceeds 2000 RPM, the outboard will automatically return down to
the maximum trim range.
Compression Check
Engine compression should be checked with the engine block at operating temperatures, all spark plugs removed, and using a
fully charged battery.
1. Remove spark plugs.
2. Install compression gauge in spark plug hole.
a - Compression gauge
a b - 14 mm adapter
5525
Compression Tester with Adapter SnapOn EEPV303B

3. Crank the engine over until the compression reading peaks on the gauge. Record the reading.
4. Check and record compression of each cylinder. The highest and lowest reading recorded should not differ by more than
15%. A reading below 827.4 kPa (120 psi) may indicate a total engine wear problem. The following example chart
below, is not a representation of compression values specific to the engine that is actually tested. It is only an
example.
Compression Test Differences

Condition Maximum Reading Minimum Reading
Good 1241 kPa (180 psi) 1062 kPa (154 psi)
Bad 1172 kPa (170 psi) 972.2 kPa (141 psi)
5. To find the maximum allowable minimum compression reading difference, use this formula; highest compression reading x
0.85 = the lowest allowable difference. 1241 kPa x 0.85 = 1054.85 kPa (180 x 0.85 = 153 psi).
6. Compression check is important because an engine with low or uneven compression cannot be tuned successfully to give
peak performance. It is essential therefore, that improper compression be corrected before proceeding with an engine
tuneup.
7. A variance of more than 103.4 kPa (15 psi) indicates the need for a powerhead inspection/disassembly.
Cylinder Leakage Testing

Engine Firing Order
Cylinder sequence 1342
NOTE: Cylinder leakage testing, along with compression testing, can help the mechanic pinpoint the source of a mechanical
failure by gauging the amount of leakage in an engine cylinder. Refer to the manufacturer's tester instructions for proper testing
procedures.
Cylinder Leakage Tester SnapOn EEPV309A
1. Remove the spark plugs from cylinders 2, 3, and 4.

2. Rotate the engine clockwise until resistance is felt.
3. Continue to rotate flywheel so the timing marks on the flywheel and cylinder block are in alignment. This will be the
compression stroke for cylinder #1.
4. Remove the spark plug from cylinder #1.
5. Complete the cylinder leak down test on the #1 spark plug hole. Refer to the manufacturer's tester instructions for proper
testing procedures.
6. After testing cylinder #1, install a dial indicator on the next firing order sequence cylinder.
7. Rotate the flywheel so the piston is at TDC.
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8. Complete the cylinder leak down test.
9. Proceed with the succeeding firing order cylinder TDC and complete the cylinder leak down test.
10. Complete the procedure in sequence on the remaining cylinders.
Analysis
Due to standard engine tolerances and engine wear, no cylinder will maintain a 0% of leakage. It is important only that cylinders
have somewhat consistent reading between them. Differences of 15 to 30% indicate excessive leakage. Larger engines tend to
have a larger percentage of cylinder leakage than smaller engines.
If excessive leakage is present, first check that the piston is at top dead center of its compression stroke. Leakage will naturally
occur if the exhaust or intake valve is open.
To determine the cause of high percentage leaks, you must locate where the air is escaping from. Listen for air escaping
through the intake, adjacent spark plug holes, exhaust pipe, and crankcase oil fill plug. Use the following table to aid in locating
the source of cylinder leakage.
Air Escaping From Possible Location

Air induction Intake valve
Exhaust system Exhaust valve
Oil fill plug Piston/rings
Adjacent cylinder Head gasket
Painting Procedures
! WARNING
Continuous exposure to airborne particles such as chemical vapors, dust, or spray can cause serious injury or death. Ensure
that the work area is properly ventilated and wear protective eyeware, clothing, and respirators.
Propellers
1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse ScotchBrite disc or belts.
2. Feather edges of all broken paint edges. Try not to sand through the primer.
3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or equivalent (Xylene or M.E.K.).
4. If bare metal has been exposed, use Mercury/Quicksilver Light Gray Primer.
5. Allow a minimum of one hour dry time and no more than one week before applying the finish coat.
6. Apply the finish coat using Mercury/Quicksilver EDP Propeller Black.
Gear Housing
The following procedures should be used in refinishing gear housings. This procedure will provide the most durable paint
system available in the field. The materials recommended are of high quality and approximate marine requirements. The
following procedure will provide a repaint job that compares with a properly applied factory paint finish. It is recommended the
listed materials be purchased from a local Ditzler Automotive Finish Supply Outlet. The minimum package quantity of each
material shown following is sufficient to refinish several gear housings.
1. Wash the gear housing with a muriatic acid base cleaner to remove any type of marine growth, and rinse with water.
2. Wash the gear housing with soap and water. Rinse with clean water.
3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only. Feather edge all
broken paint edges.
4. Clean gear housing thoroughly with DX330 Wax and Grease Remover.
5. Spot repair surfaces where bare metal is exposed with DX503 Alodine Treatment.
IMPORTANT: Do not use aerosol spray paints as the paint will not properly adhere to the surface, nor will the coating be
sufficiently thick to resist future paint blistering.
6. Mix Epoxy Chromate Primer DP90LF with equal part catalyst DP402LF per the manufacturer's instructions. Allow proper
induction period for permeation of the epoxy primer and catalyst.
7. Allow a minimum of one hour drying time and no more than one week before the top coat application.
8. Use Ditzler Urethane DU9300 for Mercury Black, DU34334 for Mariner Grey, DU35466 for Force Charcoal, DU33414M for
Sea Ray White, and DFHS 37372H for Verado Silver. Catalyze all five colors with Ditzler DU5 catalyst mixed 1:1 ratio.
Reduce with solvents per Ditzler label.
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! WARNING
Continuous exposure to airborne particles such as chemical vapors, dust, or spray can cause serious injury or death. Ensure
that the work area is properly ventilated and wear protective eyeware, clothing, and respirators.
NOTE: Apply one half to one mil even film thickness with a spray gun. Allow the paint to flash off for five minutes before
applying the second even coat of one half to one mil film thickness. Urethane paint will dry to the touch in a matter of
hours, but will remain sensitive to scratches and abrasions for a few days.
9. The type of spray gun used will determine the proper reduction ratio of the paint.
IMPORTANT: Do not paint the sacrificial anode.
10. Cut out a cardboard plug for trim tab pocket to keep paint off of mating surface to maintain good continuity circuitry
between trim tab and gear housing.
Decal Removal
1. Mark decal location before removal to assure proper alignment of new decal.
2. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing old decal.
3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water.
4. Thoroughly dry decal contact area and check for a completely cleaned surface.
Decal Application
Application Tips
1. Ensure that the surrounding work area and the surface are properly cleaned to avoid contamination.
2. Ensure that the surface and the ambient air temperature is within the specified range.
3. Ensure that your hands are clean and dry.
4. Ensure that the paper liner on the decal does not become wet. A wet paper liner is very difficult to remove.
5. Use the recommended plastic applicator. The applicator should be new and must not be damaged.
a. If the decal has a premask, use the squeegee only.
b. If the decal does not have a premask, use a low friction sleeve or felt squeegee to prevent scratching or damaging
the decal and cowl.
6. Use firm pressure on the squeegee with overlapping strokes.
7. Remove the premask and application tape at a 180 angle to the decal.
8. Puncture the air bubbles with an air release tool or straight pin. Do not use a knife or razor blade.
9. Immediately squeegee the entire decal after removing the premask tape.
Applying the Decal

1. Ensure that your hands are clean and dry.
2. Remove the center paper liner strip from decal if applicable.
3. Align the decal according to the reference placement drawing and apply light pressure on the center strip location.
50526
4. Align the decal and secure one side of the decal with your hand.
5. Lightly hinge the decal in half to expose the liner tape and remove the liner paper.
6. Apply a little tension to the decal and squeegee the entire decal from the center towards the outside edge with overlapping
strokes.
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General Information
7. Lightly hinge the other half of the decal to expose the liner tape and remove the liner paper.
8. Apply a little tension to the decal and squeegee the entire decal from the center towards the outside edge with overlapping
strokes. Be sure to overlap the outside edge of the decal with the squeegee.
9. Inspect the decal closely for entrapped air bubbles. Use the squeegee to push the air bubble to the outside edge.
10. Remove the premask liner from the decal beginning at one corner and carefully pull the premask liner off and onto itself at
a 180 angle.
IMPORTANT: When the premask is removed from the decal, the pulling force loosens the adhesive at the edges of the
decal. It is imperative to squeegee the entire decal with special attention to the edges of the decal.
50338
11. Do not allow the premask to remain on the decal for more than 24 hours after installation.
12. Squeegee the complete decal including all edges after the premask liner has been removed.
Entrapped Air Removal

The microcomply adhesive has a unique pattern to the adhesive that allows entrapped air to escape through very small
channels for a faster, easier installation. Always work from the center of the decal towards the edge. If the channels are closed
off, use an air release tool or straight pin to aid in removing the bubble. Puncture one end of the bubble and use your thumb to
push the entrapped air towards the puncture site. Do not use a knife or razor blade to puncture the decal.
Final Decal Squeegee

It is recommended to use a Meguiar's Supreme Shine Microfiber Towel for the final decal squeegee. With a firm hand pressure,
work the decal from the center out to the edge. Ensure to pay attention to the edge of the decal during this final decal
squeegee.
IMPORTANT: It is imperative to squeegee the entire decal with special attention to the edges of the decal.
IMPORTANT: Do not allow the new decal to have direct sunlight contact for a minimum of 24 hours.
Cleaning and Maintenance

IMPORTANT: Never use petroleum products or strong household cleaning chemicals to clean the outside surface of the cowls.
Using petroleum products or strong household cleaning chemicals will cause damage to the decal and may damage the cowl.
IMPORTANT: Pressure wash and scrub brush with caution. Always use a wide spray pattern, lowpressure, and an angle less
than 60 to the surface when using a pressure washer. Low angle water streams can lift the decal from the surface.
General Cleaning Instruction

Rinse the surface well with lukewarm water to remove dirt.
Use a soft cloth or sponge to gently wash the surface with a mild dishwashing soap with lukewarm water.
Do not scrub, use a brush, or a squeegee.
Rinse the surface thoroughly.
Use a clean, soft, lintfree cloth to dry and prevent water spotting.
90-8M0082471 JULY 2014 Page 1C-17

General Information
Shipping of Hazardous Material (HazMat) and Engine/Components Containing

Hazardous Material
Outboard Service Bulletin 200807
There are a number of United States regulations regarding the shipment of hazardous material. These regulations apply not
only to shipments within the United States, but to import and export shipments as well. It is important to comply with all of these
regulations. This bulletin is intended to provide you with some basic information about some of these regulations, and provide
you with information about resources from which you can obtain additional information. It is also intended to draw your attention
to the importance of proper packaging, labeling, and shipping of hazardous material; as well as any engine or engine
component that contains hazardous material like gasoline or other fluids such as crankcase oil, gearcase oil, and hydraulic
fluid. There are also requirements for training personnel that deal with the shipment of hazardous material. This bulletin is
intended to draw your attention to some of the shipping regulations that we are aware of that might apply to your business, it is
not a complete review of all of the laws and regulations that apply to the shipment of hazardous materials. Please do not treat it
as such.
NOTE: You, as the shipper of record, are responsible for classification, packaging, hazard communication, incident reporting,
handling, and transportation of hazardous materials.
Overview of Regulations
The Hazardous Materials Regulations (HMR) specify requirements for the safe transportation of hazardous materials in
commerce by rail car, aircraft, vessel, and motor vehicle. These comprehensive regulations govern transportationrelated
activities. In general, the HMR prescribe requirements for classification, packaging, hazard communication, incident reporting,
handling, and transportation of hazardous materials. The HMR are enforced by Pipeline Hazardous Material Safety
Administration (PHMSA), Department of Transportation (DOT), Federal Aviation Administration (FAA), Federal Highway
Administration (FHWA), Federal Railroad Administration (FRA), and the United States Coast Guard (USCG).
Overview of Training Requirements

Current U.S. Department of Transportation (DOT) regulations require initial training (and recurrent training) of all employees
who perform work functions covered by the Hazardous Materials Regulations. Any employee who works in a shipping,
receiving, or material handling area; or who may be involved in preparing or transporting hazardous materials, is required to
have training. Hazardous materials transportation training is available from ShipMate, Inc. The training modules on CDROM or
online contain an interactive training program which satisfies the DOT requirement for general awareness, general safety, and
HazMat security training. A comprehensive exam is offered and Certificates of Completion are generated upon successful
completion of the program. The CDROM and online WebBased Training may be purchased from ShipMate, Inc. This also
includes an electronic version of the 49 CFR Hazardous Materials Regulations, the current Emergency Response Guidebook,
and full access to ShipMates technical staff to assist you in properly preparing hazardous materials for transport. ShipMate,
Inc. may be reached at 13103703600 or on the web at http://www.shipmate.com.
NOTE: The DOT training program does NOT include a test of any type and contains a lot of material which is not relevant (e.g.
cargo tanks). In addition, you would have to purchase the 49 CFR and the Emergency Response Guidebook separately.
Further, the DOT program provides no support technical or otherwise. For further information, view the DOT website at http://
www.dot.gov.
Shipping of Complete Engines and Major Assemblies

Complete engines cannot be transported without going through additional preparation first. Electronic fuel injection (EFI) and
direct fuel injection (DFI) engines must have the fuel system drained of fuel, not run dry because of possible damage to electric
fuel pumps. Carbureted engines must be completely run dry and have stalled due to lack of fuel. All engines must have any
remaining fluids/oils drained (including engine and gearcase oil) and hydraulic fluids (including power trim fluid) and
disconnected fluid pipes that previously contained fluid must be sealed with leakproof caps that are positively retained. Major
assemblies such as gearcases, dressed powerheads, or other components containing any fluids must be also drained prior to
shipping.
More Information on Hazardous Material

More information on hazardous material, regulations, packaging, training, etc. can be found by going to the ShipMate website:
http://www.shipmate.com or by calling:
ShipMate Inc.
Telephone + 1 (310) 3703600
Fax + 1 (310) 3705700
Email [email protected]
Page 1C-18 90-8M0082471 JULY 2014

Outboard Motor Installation
1
Section 1D - Outboard Motor Installation D
Table of Contents
Mercury Marine Validated Engine Mounting Hardware..... 1D-2 Lifting Outboard................................................................. 1D-8
Accessories Mounted to the Transom Clamp Bracket.......1D-3 Steering Cable Starboard Side Routed Cable.................1D-8
Acceptable Accessory Mounting to the Transom Drilling Outboard Mounting Holes......................................1D-9
Clamp Bracket........................................................ 1D-3 Fastening the Outboard to the Transom..........................1D-10
Unacceptable Accessory Mounting............................ 1D-3 Mounting Bolts..........................................................1D-10
Important Information.........................................................1D-4 Checking Boat Transom Construction......................1D-10
Boat Horsepower Capacity................................................ 1D-5 Fastening the Outboard to the Transom...................1D-11
Start in Gear Protection..................................................... 1D-5 Steering Link Rod Fasteners (if equipped)...................... 1D-12
Selecting Accessories for Your Outboard..........................1D-5 Electrical, Fuel Hose, and Control Cables....................... 1D-13
Fuel System Requirements............................................... 1D-5 Rigging Grommet..................................................... 1D-13
Avoiding Fuel Flow Restriction................................... 1D-5 Remote Wiring Harness........................................... 1D-14
Low Permeation Fuel Hose Requirement ..................1D-5 SmartCraft Harness and Vessel Harness Connection
EPA Pressurized Portable Fuel Tank Requirements .............................................................................. 1D-15
................................................................................ 1D-5 Battery Cable Connections.......................................1D-15
Fuel Demand Valve (FDV) Requirement....................1D-5 Fuel Hose Connection.............................................. 1D-16
Mercury Marine's Pressurized Portable Fuel Tank.....1D-6 Shift Cable Installation..............................................1D-16
Fuel Tanks..................................................................1D-6 Throttle Cable Installation.........................................1D-18
Filling the Fuel System............................................... 1D-7 Trim In Pin....................................................................... 1D-19
Installation Specifications.................................................. 1D-7
Determining Recommended Outboard Mounting Height
....................................................................................... 1D-7
90-8M0082471 JULY 2014 Page 1D-1

Lubricants, Sealants, Adhesives

95 2-4-C with PTFE O-ring seal and entire cable end 92-802859A 1
Special Tools
Flywheel Puller/Lifting Ring 91895343T02
Removes flywheel from engine. Used for lifting powerhead/engine.

14869
Transom Drilling Fixture 9198234A2
Aids in engine installation by acting as a template for engine mounting holes.
5489
Stainless Steel Tilt Pin 1749930A 1
Limits the down trim angle of the power trim equipped engines, or aids in
determining the trim out angle on nonpower trim engines.
2749
Mercury Marine Validated Engine Mounting Hardware

IMPORTANT: Mercury Marine provides validated fasteners and installation instructions, including torque specifications, with all
our outboards so they can be properly secured to boat transoms. Improper installation of the outboard can cause performance
and reliability issues which can lead to safety concerns. Follow all of the instructions relating to the outboard installation. DO
NOT mount any other accessory onto the boat with the fasteners provided with the outboard. For example, do not mount a tow
sports bar or boarding ladder onto the boat using the mounting hardware included with the outboard. Installing other products
onto the boat that utilize the outboard mounting hardware will compromise the ability of that hardware to properly and safely
secure the outboard to the transom.
Outboards that require validated mounting hardware will have the following decal on the transom clamp.
51965
Page 1D-2 90-8M0082471 JULY 2014

Accessories Mounted to the Transom Clamp Bracket

Mercury Marine has been made aware that certain aftermarket marine accessories, such as emergency boarding ladders,
shallow water anchors, transom wedge kits, and tow sport attaching devices, have been mounted to the boat by use of the
same fasteners that secure the outboard to the transom or jack plate. Using the same fastener to secure both an accessory
and the engine to the boat compromises the ability of the fasteners to maintain the proper clamp load. A boat with loose engine
mounting fasteners creates the possibility of performance, durability, and safety issues.
! WARNING
Avoid serious injury or death resulting from a loss of boat control. Loose engine fasteners could cause the transom bracket to
fail, resulting in a loss of the driver's ability to control the boat. Always ensure that the engine fasteners are tightened to the
specified torque.
Acceptable Accessory Mounting to the Transom Clamp Bracket

After the engine is mounted to the transom or jack plate in accordance with the engine installation instructions, it is acceptable
to attach an accessory to the boat by use of the unused bolt holes in the transom clamp bracket as shown in Figure 1.
The following list provides additional guidelines for mounting accessories to the transom clamp bracket.
The accessory fasteners must pass through the boat transom or jack plate.
The installation must not create interference issues, as would an accessory mounting plate resting in the radius of the
transom clamp bracket. Refer to Figure 1.
a Figure 1
f a - Minimum clearance 3.175 mm (0.125 in.)
b - Edge of accessory bracket
c - Transom clamp bracket wall
d - Radius
e - Engine supplied mounting fasteners
f - Fasteners supplied by the accessory
manufacturer installed through unused
engine mounting bracket holes
b d 54624
Unacceptable Accessory Mounting

IMPORTANT: Do not use the fasteners that secure the engine to the boat (either the transom or the jack plate) for any purpose
other than securing the engine to the boat.
90-8M0082471 JULY 2014 Page 1D-3

1. Do not mount an accessory to the transom clamp bracket in an unsupported condition. Refer to Figure 2.
54625
Figure 2
2. Do not attach an accessory to the boat by use of the engine mounting hardware. Refer to Figure 3.
Figure 3
b c a - Engine supplied mounting fasteners
b - Transom clamp bracket
c - Accessory
53523
3. Do not install wedges or plates between the transom clamp brackets and the transom (or jack plate). Refer to Figure 4.
Figure 4
a a - Boat transom or jack plate
b b - Transom clamp bracket
c - Wedge/plate
c
54058
Rigging boats, which includes proper engine installation has become more complex over the years. As a result, Mercury Marine
recommends that engines be installed only by Mercury authorized dealers. If you intend to disregard this recommendation, and
install the engine yourself, please make sure to read and comply with these instructions. Failure to comply with these
installation instructions could lead to serious injury or death.
NOTE: Do not install an accessory electric fuel pump or a fuel line primer bulb into the fuel system of this engine.
Page 1D-4 90-8M0082471 JULY 2014

Boat Horsepower Capacity

! WARNING
Exceeding the boat's maximum horsepower rating can cause serious injury or death. Overpowering the boat can affect boat
control and flotation characteristics or break the transom. Do not install an engine that exceeds the boat's maximum power
rating.
Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable
power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the
boat manufacturer.
U.S. COAST GUARD CAP ACITY

MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
26777
Start in Gear Protection

! WARNING
Starting the engine with the drive in gear can cause serious injury or death. Never operate a boat that does not have a
neutralsafetyprotection device.
The remote control connected to the outboard must be equipped with a start in neutral only protection device. This prevents the
engine from starting in gear.
Selecting Accessories for Your Outboard

Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard.
Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or
outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all selected accessories.
Fuel System Requirements

Avoiding Fuel Flow Restriction
IMPORTANT: Adding components to the fuel supply system (filters, valves, fittings, etc.) may restrict the fuel flow. This may
cause engine stalling at low speed, and/or a lean fuel condition at high RPM that could cause engine damage.
Low Permeation Fuel Hose Requirement

Required for outboards manufactured for sale, sold, or offered for sale in the United States.
The Environmental Protection Agency (EPA) requires that any outboard manufactured after January 1, 2009, must use low
permeation fuel hose for the primary fuel hose connecting the fuel tank to the outboard.
Low permeation hose is USCG Type B115 or Type A115, defined as not exceeding 15/gm/24 h with CE 10 fuel at 23 C
as specified in SAE J 1527 marine fuel hose.
EPA Pressurized Portable Fuel Tank Requirements

The Environmental Protection Agency (EPA) requires portable fuel systems that are produced after January 1, 2011, for use
with outboard engines to remain fully sealed (pressurized) up to 34.4 kPa (5.0 psi). These tanks may contain the following:
An air inlet that opens to allow air to enter as the fuel is drawn out of the tank.
An air outlet that opens (vents) to the atmosphere if pressure exceeds 34.4 kPa (5.0 psi).
Fuel Demand Valve (FDV) Requirement

Whenever a pressurized fuel tank is used, a fuel demand valve is required to be installed in the fuel hose between the fuel tank
and primer bulb. The fuel demand valve prevents pressurized fuel from entering the engine and causing a fuel system overflow
or possible fuel spillage.
90-8M0082471 JULY 2014 Page 1D-5

The fuel demand valve has a manual release. The manual release can be used (pushed in) to open (bypass) the valve in case
of a fuel blockage in the valve.
b a - Fuel demand valve installed in the fuel hose between the fuel tank and primer
a bulb
b - Manual release
c - Vent/water drain holes
c 46273
Mercury Marine's Pressurized Portable Fuel Tank

Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements. These fuel tanks
are available as an accessory or are provided with certain portable outboard models.
Special Features of the Portable Fuel Tank

The fuel tank has a twoway valve which allows air to enter the tank as the fuel is drawn to the engine, and also opens to
vent to the atmosphere if internal pressure in the tank exceeds 34.4 kPa (5.0 psi). A hissing noise may be heard as the
tank vents to the atmosphere. This is normal.
The fuel tank includes a fuel demand valve that prevents pressurized fuel from entering the engine and causing a fuel
system overflow or possible fuel spillage.
When installing the fuel tank cap, turn the cap to the right until you hear a click. This signals that the fuel cap is fully seated.
A builtin device prevents overtightening.
The fuel tank has a manual vent screw which should be closed for transportation and open for operation and cap removal.
Since sealed fuel tanks are not vented, they will expand and contract as the fuel expands and contracts during heating and
cooling cycles of the outside air. This is normal.
Removing the Fuel Cap
b a - Fuel cap
a b - Manual vent screw
c - Tab lock
c
46290
IMPORTANT: Contents may be under pressure. Rotate the fuel cap 1/4 turn to relieve pressure before opening.
1. Open the manual vent screw on top of the fuel cap.
2. Turn the fuel cap until it contacts the tab lock.
3. Press down on the tab lock. Rotate the fuel cap 1/4 turn to relieve the pressure.
4. Press down on the tab lock again and remove the cap.
Directions for Using the Pressurized Portable Fuel Tank

1. When installing the fuel tank cap, turn the cap to the right until you hear a click. This signals that the fuel cap is fully seated.
A builtin device prevents overtightening.
2. Open the manual vent screw on top of the cap for operation and cap removal. Close the manual vent screw for
transportation.
3. For fuel hoses that have quick disconnects, disconnect the fuel line from the engine or fuel tank when not in use.
4. Follow Filling Fuel Tank instructions for fueling.
Fuel Tanks
Portable Fuel Tank
Select a suitable location in the boat within the engine fuel line length limitations and secure the tank in place.
Permanent Fuel Tank

Permanent fuel tanks should be installed in accordance with industry and federal safety standards, which include
recommendations applicable to grounding, antisiphon protection, ventilation, etc.
Page 1D-6 90-8M0082471 JULY 2014

Filling the Fuel System

NOTE: For initial start of a new engine, or for an engine that ran out of fuel or was drained of fuel, the fuel system should be
filled as follows:
Turn the ignition key switch to the "ON" position for approximately one minute. This operates the fuel lift pump. Turn the ignition
key switch back to the "OFF" position and then return the ignition key switch to the "ON" position again for an additional minute.
Turn the ignition key switch back to the "OFF" position. The filling of the fuel system is complete.
Installation Specifications
a
a - Minimum transom opening
a b b - Engine centerline for dual engine 66.0 cm
(26 in.) minimum
18552
Minimum Transom Opening

Single engine 84.2 cm (33 in.)
Dual engine 149.9 cm (59 in.)
Determining Recommended Outboard Mounting Height

63.5 cm
(25 in.)
a - The solid line is recommended to
60.9 cm
(24 in.) determine the outboard mounting height
e c b b - The broken lines represent the extremes
58.4 cm
(23 in.) of known successful outboard mounting
height dimensions
56.0 cm
(22 in.) c - This line may be preferred to determine
a outboard mounting height dimension, if
53.3 cm
(21 in.) maximum speed is the only objective
d - This line may be preferred to determine
50.8 cm
(20 in.) outboard mounting height dimension for
e d dual outboard installation
48.2 cm
(19 in.) e - Outboard mounting height (height of
outboard mounting brackets from bottom
10 20 30 40 50 60 70 80 of boat transom). For heights over
56.0 cm (22 in.), a propeller that is
f 18562 designed for surfacing operation is
usually preferred.
f - Maximum boat speed (MPH) anticipated
NOTICE
1. The outboard should be mounted high enough on the transom so the exhaust relief hole will stay at least 25.4 mm (1 in.)
above the waterline when the engine is running at idle speed. Having the exhaust relief hole above the waterline will
prevent exhaust restrictions. Exhaust restrictions will result in poor performance at idle.
2. Add 12.7 cm (5 in.) for XL models to the listed outboard mounting heights.
3. The mounting height of the outboard must not exceed 63.5 cm (25 in.) for L models, 76 cm (30 in.) for XL models.
Mounting the outboard higher may cause damage to the gearcase components.
Increasing the mounting height will usually:

Reduce steering torque
Increase top speed
90-8M0082471 JULY 2014 Page 1D-7

Increase boat stability
Cause propeller to break loose during planing
Lifting Outboard
1. Remove the top cowl.
2. Install the lifting base to the flywheel using three bolts. Tighten the bolts securely.
3. Thread the lifting eye into the lifting base.
4. Connect a hoist that has a minimum lift capacity of 450 kg (1000 lb) to the lifting eye.
5. Lift the outboard and place it on the transom.
a - Lifting base
b b - Lifting eye
a
53797
Steering Cable Starboard Side Routed Cable

1. Lubricate the Oring seal and the entire cable end.
95
3724

95 2-4-C with PTFE O-ring seal and entire cable end 92-802859A 1
2. Insert the steering cable into the tilt tube.
3725
Page 1D-8 90-8M0082471 JULY 2014

3. Tighten the nut to the specified torque.
3727

Nut 47.5 35
Drilling Outboard Mounting Holes

IMPORTANT: Before drilling any mounting holes, carefully read Determining Recommended Outboard Mounting Height
and install outboard to the nearest recommended mounting height.
1. Mark four mounting holes on the transom using the transom drilling fixture.
b a - Drill guide holes

b - Transom drilling fixture
c - Transom centerline
c 2757
Transom Drilling Fixture 9198234A2

2. Drill four 13.5 mm (17/32 in.) mounting holes.
3973
90-8M0082471 JULY 2014 Page 1D-9

Fastening the Outboard to the Transom

Mounting Bolts
Outboard Transom Mounting Hardware Supplied with Outboard
Part Number Part Name Description
677551 Outboard mounting bolt 20 x 4.50 in. long (2.25 in. thread)
82671117 Nylon insert locknut 20
28421 Flat washer 1.50 in. diameter
54012 Flat washer 0.875 in. diameter
Available Outboard Mounting Bolts

Part Number Description
67755005 20 x 2.50 in. long (1.25 in. thread)
8M0033366 20 x 5.00 in. long (3.25 in. thread)
Checking Boat Transom Construction

IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold
75 Nm (55 lbft) of torque without the boat transom yielding or cracking. If the boat transom yields or cracks under this torque,
the construction of the transom may not be adequate. The boat transom must be strengthened or the load carrying area
increased.
a - Transom yielding under bolt torque

b - Transom cracking under bolt torque
b 18961
a
Use a dial torque wrench to determine transom strength. If the bolt or nut continues to turn without the torque reading on the
dial increasing, it is an indication that the transom is yielding. The load area can be increased by using a larger washer or a
transom reinforcement plate.
a
a - Large transom washer
b - Transom reinforcement plate
b
33962
Page 1D-10 90-8M0082471 JULY 2014

Fastening the Outboard to the Transom

IMPORTANT: The transom mounting surface must be flat within 3.17 mm (0.125 in.). No step in the transom mounting surface
is allowed. The inside transom mounting bolt washer surface must be flat within 3.17 mm (0.125 in.).
a a - Step (not allowed)

b - Gap between transom clamp and boat transom (not
allowed)
51817
IMPORTANT: Clearance must be maintained between the vessel transom and the outboard transom bracket relief radius area.
Failure to maintain clearance may damage the transom bracket and cause the transom bracket to fail. Adjustments to the
position of the Mercury Marine transom drilling fixture may be required to ensure proper clearance of the transom bracket relief
radius area.
51867
Installation
1. Apply marine sealer to the shanks of the bolts, not to the threads.
2. Fasten the outboard with the correct mounting hardware. Tighten the locknuts to the specified torque.
IMPORTANT: Ensure that a minimum of two full threads of the mounting bolts extend beyond the locknut after tightening.
The locknut must be drawn tight while still engaging the bolt threads and not contacting the shank of the bolt.
90-8M0082471 JULY 2014 Page 1D-11

NOTE: For a more accurate torque reading, tighten the mounting locknuts rather than the outboard mounting bolts.
a- 0.500 in. diameter outboard mounting bolt (4)

d
b- 0.875 in. flat washer (4)
c c- Nylon insert locknut (4)
a
d- 1.500 in. flat washer (4)
e- Marine sealer apply to the shank of the
bolts, not the threads
e
b
c
d a
40952

A decal on the transom bracket reminds the owner to check the fasteners securing the outboard to the transom before each
use.
51985
Decal on the transom bracket
Steering Link Rod Fasteners (if equipped)

IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using a special washer
head bolt ("a" Part Number 10856680) and selflocking nylon insert locknuts ("c" and "d" Part Number 11826709113).
These locknuts must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link
rod to disengage.
Page 1D-12 90-8M0082471 JULY 2014

! WARNING
Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This
can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown
within or out of the boat. Always use required components and follow instructions and torque procedures.
a a- Special washer head bolt (10856680)

b b- Flat washers
c- Nylon insert locknut (11826709113)
c d- Nylon insert locknut (11826709113)
d 47709

Special washer head bolt 27 20
Nylon insert locknut "d" 27 20
Tighten until it seats, then back off 1/4
Nylon insert locknut "c"
turn
Assemble steering link rod to steering cable with two flat washers and nylon insert locknut. Tighten locknut until it seats, then
back nut off 1/4 turn.
Assemble steering link rod to engine with special washer head bolt and locknut. First torque special washer head bolt, then
torque locknut to specifications.
Electrical, Fuel Hose, and Control Cables

Rigging Grommet
Installation
IMPORTANT: Sufficient slack must exist in wiring harnesses, battery cables, and hoses, that are routed between the rigging
grommet and engine attachment points, to relieve stress and prevent hoses from being kinked or pinched.
1. Route the hoses, wiring, and cables through the rigging adapter and correct opening in the rigging grommet as shown.
a- Screws M6 x 30 (2)
b- Screw M6 x 50
c- Rigging adapter
d- Rigging grommet
c d e- Battery cable opening
b f- Remote 14 pin boat harness opening
g- SmartCraft harness or additional harness
e opening
f h - Accessory harness opening
l i - Shift cable opening
j - Speedometer tube opening
k - Fuel hose opening
l - Throttle cable opening
a k g
j h
i
53867
2. Fasten the rigging grommet and rigging adapter with two M6 x 30 screws and one M6 x 50 screw. Tighten the screws to
the specified torque.
90-8M0082471 JULY 2014 Page 1D-13

3. Secure the wiring, hoses, and cables together with a cable tie.
NOTICE
Inspect the position of the hose clamp located on the fuel hose to ensure that it will not chafe or cut into the adjacent wiring
harnesses.
53884
Cable tie

Screws for attaching the rigging adapter 6 53
Remote Wiring Harness

Route the remote 14 pin boat harness through the rigging grommet. Remove the harness cover and connect the remote
harness to the 14 pin connector on the engine harness. Secure the harness with the retainer.
a - Remote 14 pin boat harness

c b - Retainer
b c - 14 pin connector
53886
Page 1D-14 90-8M0082471 JULY 2014

SmartCraft Harness and Vessel Harness Connection

1. If the boat is equipped with a SmartCraft and/or vessel (accessory) harness, remove the ignition coil cover located on the
port side of the engine.
53826
2. Route the SmartCraft and/or vessel harness through the rigging grommet and connect it to the connector.
a - Vessel (accessory) harness connector

b - SmartCraft harness connector
53857
Battery Cable Connections

Single Outboard
a a - Red sleeve Positive (+)

b - Black sleeve Negative ()
c - Cranking battery
(+)
b c
(-) 15496
90-8M0082471 JULY 2014 Page 1D-15

Dual Outboards
Connect a common ground cable (wire size same as engine battery cables) between negative () terminals on starting
batteries.
a a- Red sleeve Positive (+)

b- Black sleeve Negative ()
c- Ground cable
d- Cranking battery
b
a (-)
d
b
c (-)
d
15497
Fuel Hose Connection

Install and secure the quick disconnect fuel hose fitting with a hose clamp. Position the hose clamp so that it will not chafe or
cut into an adjacent wiring harness.
NOTICE
Inspect the position of the hose clamp to ensure that it will not chafe or cut into the adjacent wiring harnesses.
Fuel Hose Size

Minimum fuel hose inside diameter (ID) is 8 mm (5/16 in.) with separate fuel hose/fuel tank pickup for each engine.
53883
Quick disconnect fuel hose fitting
Shift Cable Installation

Install cables into the remote control following the instructions provided with the remote control.
NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is
moved out of neutral.
1. Position the remote control and outboard into neutral position.
Page 1D-16 90-8M0082471 JULY 2014

2. Center the shift cable anchor pin with the neutral detent alignment mark.
a - Shift cable anchor pin

b - Neutral detent alignment mark
a
b
53873
3. Locate the center point of the slack or lost motion that exists in the shift cable as follows:
a. Move the remote control handle from neutral into forward and advance the handle to full speed position. Slowly return
the handle back to the neutral position. Place a mark "a" on the cable against the cable end guide.
b. Move the remote control handle from neutral into reverse and advance the handle to full speed position. Slowly return
the handle back to the neutral position. Place a mark "b" on the cable against the cable end guide.
c. Make a center mark "c," midway between marks "a" and "b." Align the cable end guide against this center mark when
installing the cable to the engine.
6098
4. Position the remote control into neutral.

5. Place the barrel cup into the barrel pocket.
6. Align the shift cable end guide with the center mark made in step 3. Place the shift cable on the anchor pin. Adjust cable
barrel so it slips freely into the barrel cup.
7. Secure the shift cable to the anchor pin with the shift cable retainer.
8. Lock the barrel in place with the cable latch.
a
b a - Shift cable retainer
b - Cable latch
53872
9. Check shift cable adjustments as follows:

a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the
cable end.
b. Shift remote control into neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel away from
the cable end. Repeat steps a and b.
90-8M0082471 JULY 2014 Page 1D-17

c. Shift remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust the
barrel away from the cable end. Repeat steps a through c.
d. Shift remote control back to neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel closer
to the cable end. Repeat steps a through d.
Throttle Cable Installation

Install cables into the remote control following the instructions provided with the remote control.
1. Shift remote control into the neutral (N) position.
26838
2. Install the throttle cable onto the throttle cam anchor pin and secure with the anchor pin latch.
3. Adjust the cable barrel so that the throttle cam timing mark will align with the throttle lever.
a - Anchor pin latch

b - Throttle lever
c - Throttle cam timing mark
a
b
c
53875
4. Place the barrel cup onto the barrel. Place the cable barrel and barrel cup into the barrel retainer.
5. Lock the cable in place with the cable latch.
b a - Anchor pin latch

b - Cable latch
a
53874
6. Press on the cable latch to ensure the cable latch locks onto the bracket.
Page 1D-18 90-8M0082471 JULY 2014

7. Pull up on the throttle cable near the cable latch to confirm the cable latch has locked onto the bracket.
54183
Trim In Pin
! WARNING
Some boats, particularly some bass boats, are built with a greater than normal transom angle, which will allow the outboard to
be trimmed further in or under. This greater trim under capability is desirable to improve acceleration, reduce the angle and
time spent in a bow high boat during planing off, and in some cases, may be necessary to plane off a boat with aft livewells,
given the variety of available propellers and height range of engine installations.
However, once on plane, the engine should be trimmed to a more intermediate position to avoid a bowdown planing condition
called plowing. Plowing can cause bow steering or oversteering and inefficiently consumes horsepower.
a - Tilt pin (not included with engine)
2688
Stainless Steel Tilt Pin 1749930A 1
The owner may decide to limit the trim in. This can be accomplished by purchasing a stainless steel tilt pin from your dealer and
insert it in whatever adjustment hole in the transom brackets is desired. A nonstainless steel shipping bolt should not be used in
this application other than on a temporary basis.
90-8M0082471 JULY 2014 Page 1D-19

Notes:
Page 1D-20 90-8M0082471 JULY 2014

Storage
1
Section 1E - Storage E
Table of Contents
Storage Preparation...........................................................1E-2 Gearcase........................................................................... 1E-3
Fuel System................................................................1E-2 Positioning Outboard for Storage.......................................1E-3
Protecting External Outboard Components....................... 1E-2 Battery Storage.................................................................. 1E-3
Protecting Internal Engine Components............................ 1E-2 Winter Storage of Batteries................................................1E-3
90-8M0082471 JULY 2014 Page 1E-1

Storage

119 Storage Seal Rust Inhibitor Spark plug holes 92-858081K03

Fuel System Treatment and
124 Fuel tank 92-8M0047932
Stabilizer
Storage Preparation
The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by
freezing of trapped water.
The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage
(two months or longer).
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
Fuel System
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage
the fuel system. If the gasoline being used contains alcohol, it is advisable to drain as much of the remaining gasoline as
possible from the fuel tank, remote fuel line, and engine fuel system.
IMPORTANT: This outboard is equipped with a closed fuel system when the engine is not running. With this closed system,
fuel within the engine's fuel system, other than the fuel tank, will remain stable during normal storage periods without the
addition of fuel treatment stabilizers.
Fill the fuel tank and engine fuel system with treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed
with the following instructions.
Portable fuel tank Pour the required amount of Fuel System Treatment and Stabilizer (follow instructions on container)
into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel.
Permanently installed fuel tank Pour the required amount of Fuel System Treatment and Stabilizer (follow instructions on
container) into a separate container and mix with approximately one liter (one quart) of gasoline. Pour this mixture into fuel
tank.

Fuel System Treatment
124 Fuel tank 92-8M0047932
and Stabilizer
Protecting External Outboard Components

Touch up any paint nicks. See your dealer for touchup paint.
Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control
anodes).

Protecting Internal Engine Components

Change the engine oil and filter.
Disconnect the fuel pumps from the engine harness connector.
Remove the spark plugs.
Spray approximately 30 ml (1 fl oz) of Storage Seal Rust Inhibitor into each spark plug hole.
Page 1E-2 90-8M0082471 JULY 2014

Storage

Storage Seal Rust
119 Spark plug holes 92-858081K03
Inhibitor
Actuate key/push button start switch to crank the engine through one start cycle, which will distribute the storage seal
throughout the cylinders.
Connect the fuel pumps to the engine harness connector.
Install the spark plugs.
Gearcase
Drain and refill the gearcase lubricant.
Positioning Outboard for Storage

Store outboard in an upright (vertical) position to allow water to drain out of the outboard.
NOTICE
Storing the outboard in a tilted position can damage the outboard. Water trapped in the cooling passages or rain water
collected in the propeller exhaust outlet in the gearcase can freeze. Store the outboard in the full down position.
Battery Storage
Follow the battery manufacturer's instructions for storage and charging.
Remove the battery from the boat and check water level. Charge if necessary.
Store the battery in a cool, dry place.
Periodically check the water level and charge the battery during storage.


90-8M0082471 JULY 2014 Page 1E-3

Storage
Notes:
Page 1E-4 90-8M0082471 JULY 2014

Ignition
Electrical
Section 2A - Ignition
Table of Contents 2
A
Ignition Specifications........................................................ 2A-2 Cylinder Block Coolant Temperature Sensor Removal
Ignition Components.......................................................... 2A-4 .............................................................................. 2A-25
Electrical Components....................................................... 2A-6 Cylinder Block Coolant Temperature Sensor
Troubleshooting Guide.......................................................2A-8 Installation............................................................. 2A-26
Engine Harness Connector..............................................2A-10 Manifold Absolute Pressure (MAP) Sensor .................... 2A-27
Engine Control Module (ECM)......................................... 2A-10 Manifold Absolute Pressure Sensor Test................. 2A-27
Engine Control Module Removal.............................. 2A-11 Manifold Absolute Pressure Sensor Removal.......... 2A-28
Engine Control Module Installation........................... 2A-12 Manifold Absolute Pressure Sensor Installation....... 2A-29
Wire Color Code Abbreviations........................................2A-13 Idle Air Control (IAC)........................................................2A-29
Main Power Relay (MPR)................................................ 2A-13 Idle Air Control (IAC) Testing....................................2A-30
Main Power Relay ....................................................2A-13 IAC Removal.............................................................2A-31
Main Power Relay Test.............................................2A-13 IAC Inspection and Installation................................. 2A-31
Ignition Coil...................................................................... 2A-16 Manifold Air Temperature (MAT) Sensor ........................ 2A-32
Ignition Coils............................................................. 2A-16 Manifold Air Temperature Sensor Test.....................2A-32
Ignition Coil Circuit Voltage Test...............................2A-16 Manifold Air Temperature Sensor Removal..............2A-33
Ignition Coil Resistance Test.................................... 2A-18 Manifold Air Temperature Sensor Installation...........2A-34
Spark Plug Wire Resistance Test.................................... 2A-20 Oil Pressure Sensor.........................................................2A-35
Crankshaft Position Sensor (CPS)...................................2A-20 Oil Pressure Sensor Test..........................................2A-35
Crankshaft Position Sensor Test.............................. 2A-20 Oil Pressure Sensor Removal.................................. 2A-36
Crankshaft Position Sensor Removal....................... 2A-21 Oil Pressure Sensor Installation............................... 2A-37
Crankshaft Position Sensor Installation.................... 2A-22 Shift Position Sensor........................................................2A-37
Throttle Position Sensor (TPS)........................................ 2A-23 Shift Position Sensor Test........................................ 2A-38
Throttle Position Sensor Test................................... 2A-23 Shift Position Sensor Removal................................. 2A-38
Cylinder Block Coolant Temperature Sensor...................2A-24 Shift Position Sensor Installation.............................. 2A-39
Cylinder Block Coolant Temperature Sensor Test... 2A-24
90-8M0082471 JULY 2014 Page 2A-1

Ignition
Full throttle RPM 75/80 45005500
Full throttle RPM 90/100/115 50006000
Idle RPM in neutral 700 50
Ignition type Digital inductive
Firing order 1342
Ignition timing at idle Approximately 2 BTDC; ECM controlled
Ignition timing at WOT ECM controlled
ECM overspeed limiter
75/80 Activates at 5650 RPM
90/100/115 Activates at 6150 RPM

Loctite 567 PST Pipe Cylinder block coolant temperature sensor threads
9 92-809822
Sealant Oil pressure sensor threads
66 Loctite 242 Threadlocker Ignition coil mounting screw threads 92-809821
Special Tools
Spark Gap Tester 91850439T 1
Provides a visual indication of spark/coil efficiency.

7513
CDS G3 Diagnostic Interface Tool With

8M0046124
Harness
Provides diagnostic support for the Computer Diagnostic System.
41993
DMT 2004 Digital Multimeter 91892647A01
Measures RPM on spark ignition (SI) engines, ohms, amperes, AC and DC

V Hz
H z TEMP
mA
A
voltages; records maximums and minimums simultaneously, and accurately
reads in high RFI environments.
mV IG
OFF IP
TEMP
A mA COM V Hz
4516
Page 2A-2 90-8M0082471 JULY 2014

Ignition
Notes:
90-8M0082471 JULY 2014 Page 2A-3

Ignition
Ignition Components
4
3
1
2 7
6
55122
Page 2A-4 90-8M0082471 JULY 2014

Ignition
Ignition Components
Torque
Ref. No. Qty. Description Nm lbin. lbft
1 2 Dual output ignition coil
2 4 Screw (M6 x 25) 10.2 90
3 1 Spark plug set
4 4 Spark plug
5 1 Coil cover
6 1 High tension lead tray
7 2 Nylon pushin screw
90-8M0082471 JULY 2014 Page 2A-5

Ignition
Electrical Components
2
7
19 18 6 5 43
14 17
3
2
14 15 16 17 6 548
10
2 9
4 3
6 5 2
12 3
13 4
5
6
3
22
11
4
6 5
21
20
55120
Page 2A-6 90-8M0082471 JULY 2014

Ignition
Electrical Components
Torque
1 1 Engine harness
2 6 Cable tie clip
3 7 Bushing
4 7 Grommet
5 7 Washer
6 7 Screw (M6 x 25) 10 88.5
7 1 Electrical plate
8 1 Screw (M8 x 10) 24 212 17.7
9 1 Nut (M8)
10 1 Lockwasher
11 1 Engine control module
12 1 Clip
13 1 Nylon nut 9 80
14 4 Relay
15 1 Fuse cover with spares
16 1 Fuse cover
17 4 Relay clip
18 4 Grommet
19 1 Electrical plate cover
20 1 Voltage regulator
21 6 Screw (M6 x 30) 10 88.5
22 1 Voltage regulator gasket
90-8M0082471 JULY 2014 Page 2A-7

Ignition
Troubleshooting Guide
Spark Gap Tester 91850439T 1
8M0046124
Harness
1. Engine Cranks but Will Not Start

Cause Action
1.0 Weak battery or bad starter motor, battery Replace/recharge battery.
voltage drops below 11 volts while cranking (ECM Inspect the condition of the starter motor.
cuts out below 8 volts) (fuel pumps require 9 volts) Check condition of the battery terminals and cables.
Turn the key switch to the "ON" position to verify the fuel pump runs for
1.1 No fuel
five seconds and then turns off.
Measure the fuel pressure at the fuel rail.
1.2 Low fuel pressure
Fuel pressure should be 280310 kPa (40.645.0 psi).
1.3 Flywheel key sheared or is not installed Remove the flywheel and inspect.
1.4 Blown fuse Inspect the fuses in the fuse holder and replace if blown.
Listen for the relay to click when the key switch is turned on. If the relay
1.5 Main power relay is not functioning does not click, inspect the harness and the connector pins for damage,
verify the 15 amp fuse is not blown.
Disconnect the engine harness from the fuel supply module.
Remove spark plugs from each cylinder.
Install the spark gap tester to each ignition coil. Crank the engine, or use
1.6 Spark plugs1. the CDS G3 Diagnostic Interface tool output load test for each ignition coil,
and observe spark. If no spark is present, inspect the fuse. If the fuse is
good, replace the appropriate ignition coil. If spark is present, replace the
spark plugs.
Disconnect the engine harness from both coils.
Measure for resistance between the engine harness coil connectors red/
yellow wires (terminal B). High resistance indicates corrosion or a
damaged splice connection in the engine harness. An open condition
indicates the harness must be repaired at the splice location or the
1.7 Spark from one coil only
harness must be replaced.
Measure for resistance between the engine harness coil connector
terminal A and the engine harness ECM connector. (Pin 32 for coil #1, pin
33 for coil #2.) High resistance indicates corrosion. An open condition
indicates the harness must be repaired or replaced.
Fuel injection system:
Listen for injector ticking when cranking or connect a spare injector to
each respective harness.
Ignition system:
Install the spark gap tester between the ignition coil and engine
ground. Check for strong spark while cranking the engine.
1.8 ECM not functioning Check for battery voltage (red/blue lead) at ignition coils.
Check for blown fuse.
Check for battery voltage to fuse from main power relay (red/purple
lead).
Check for a shorted stop wire (black/yellow lead).
Check all power connections.
Defective ECM.
1. Spark jumping the gap from all cylinders at the same time in the spark gap tool may cause interference in the ECM. The interference may cause
the absence of spark on some cylinders and a false diagnosis of a no spark condition. Crank the engine over with one coil spark plug wire
connected to spark gap tool at a time or use the CDS G3 Diagnostic Interface tool to fire one coil at a time.
Page 2A-8 90-8M0082471 JULY 2014

Ignition
1. Engine Cranks but Will Not Start

Cause Action
Verify the magnet is not missing from end of the sensor.
Perform an ohm resistance check of the sensor. Refer to the specifications
1.9 Crankshaft position sensor is not functioning
for ohm test.
Defective crankshaft position sensor.
2. Engine Will Not Crank

Cause Action
Use the CDS G3 Diagnostic Interface tool to determine proper functioning
2.0 Defective main power relay
of the main power relay.
2.1 Main power relay fuse blown Check for blown fuse.
2.2 Lanyard stop switch is in wrong position Reset the lanyard stop switch.
3. Engine Cranks, Starts, and Stalls

Cause Action
3.0 Low fuel pressure in the fuel rail See 1.2.
3.1 Abnormally high friction in the engine Check for a scuffed piston or other sources of high friction.
3.2 Air in the fuel system/lines Crank and start the engine several times to purge. See 1.3.
3.3 Harness connections are poor from the engine
Clean and inspect all harness connections.
to the helm
3.4 Flywheel misaligned during installation Flywheel key sheared or missing. See 1.3.
4. Engine Idle is Rough

Cause Action
Replace the spark plug if carbon bridges electrode gap, if it is completely
black, or if it is not firing and is wet with fuel.
4.1 Fouled spark plug
NOTE: If the spark plug is gray or completely black with aluminum specs,
this indicates a scuffed piston.
4.2 Failed fuel injector Refer to the specifications for the ohm test.
4.3 Bad ignition coil/weak spark Refer to the specifications for the ohm test.
4.4 Flywheel misaligned during installation Flywheel key sheared or missing. See 1.3.
4.5 Engine not running on all cylinders Inspect for mechanical damage.
5. Engine Runs Rough Below 3000 RPM

Cause Action
5.2 Low fuel pressure in the fuel rail Measure fuel pressure. See 1.2.
5.3 Bad ignition coil/weak spark Refer to the specifications for the ohm test.
5.4 Engine not running on all cylinders Inspect for mechanical damage.
6. Engine Runs Rough Above 3000 RPM

Cause Action
90-8M0082471 JULY 2014 Page 2A-9

Ignition
6. Engine Runs Rough Above 3000 RPM

Cause Action
6.2 Low fuel pressure in the fuel rail Measure fuel pressure. See 1.2.
Refer to the SmartCraft gauges for low oil, engine overheat, or sensor/
6.3 Speed reduction actuator out of range. The CDS G3 Diagnostic Interface tool will help
identify proper functioning of sensors/actuator.
6.4 Defective crankshaft position sensor Refer to the CDS G3 Diagnostic Interface tool for fault identification.
7. Speed Reduction (RPM Reduced to Idle)

Cause Action
7.1 Sensor/actuator is out of range Refer to the CDS G3 Diagnostic Interface tool for fault identification.
7.2 Low oil pressure Check the oil dipstick for proper oil level.
7.3 Engine overheat Check the engine cooling system for proper functioning.
8. Speed Reduction (RPM Reduced to 75%)

Cause Action
8.1 Sensor/actuator is out of range Refer to the CDS G3 Diagnostic Interface tool for fault identification.
8.2 Low oil pressure Check the oil dipstick for proper oil level.
8.3 Engine overheat Check the engine cooling system for proper functioning.
Engine Harness Connector

The engine harness utilizes a compact 70 pin watertight connector for the ECM. The connector is unique because it will lock
and unlock from the ECM with the lever incorporated in the connector.
The following graphic shows the pin number location on the connector.
17 1
33 18
50 34
66 51
70 69 68 67 48714
Engine Control Module (ECM)

The ECM requires 8 volts minimum to operate. If the ECM should fail, the engine will stop running. The inputs to the ECM can
be monitored and tested using the CDS G3 Diagnostic Interface tool.

8M0046124
Harness
The ECM:
Calculates the precise fuel and ignition timing requirements based on engine speed, throttle position, manifold absolute
pressure (MAP), manifold air temperature (MAT), and cylinder block coolant temperature.
Directly controls fuel injectors, ignition coils, main power relay activation, diagnostics, Engine Guardian, start relay, idle air
control (IAC), and tachometer link (analog tachometer output or link gauge driver).
Indirectly controls the positive circuit to fuel injectors, main power relay activation, and fuel pumps.
Page 2A-10 90-8M0082471 JULY 2014

Ignition
The ECM operates in three modes: stall, start, and run. The ECM also provides for a smooth throttle response between varying
throttle positions and engine loads. A warmup mode is integrated with the run mode and disengaged after the engine
accumulates a given amount of power or engine temperature.
With the ignition key switch off, 12 volts are available from the battery at the starter solenoid, power stud, and at the alternator.
Stall mode With the ignition key switch in the "ON" position, the ECM is energized and supplies power to the main power
relay for five seconds. It also provides 5volt power to the sensors. The ECM records barometric pressure from the MAP
sensor, intake air temperature from the MAT sensor, and coolant temperature from the cylinder block coolant temperature
sensor. The ECM will use this information to establish a warmup strategy that will control fuel delivery and engine speed during
warmup and idle.
Start mode When the vessel operator turns the key switch to the "Start" position, a 12volt signal is sent to the ECM to begin
the sequence of turning the engine over by energizing the start relay. The start relay transfers battery voltage to energize the
starter solenoid. While the engine rotates, a pulse will be generated at the crankshaft position sensor, which provides the ECM
engine speed information and engages the main power relay. If the key switch is turned to the "Start" position while the engine
is running in neutral, the engine will turn off.
Run mode At approximately 500 RPM, the ECM will transition to the run mode.
The warmup strategy will continue to adjust engine speed with the fuel injector pulse width and engine spark advance until
the engine accumulates a given amount of power.
The MAT sensor, TPS, and MAP sensor are monitored to determine proper spark timing and the fuel needs necessary to
develop the amount of power asked for by the operator.
Engine Control Module Removal

1. Remove the CAN terminator resistor.
2. Pull the lock bar to release the engine harness connector.
3. Remove the connector from the ECM.
a- CAN terminator resistor

b- Engine harness connector
c- Lock bar
d c d- Jclamp
a
54851
4. Remove the three screws and washers and the Jclamp securing the ECM to the cylinder block.
a - Screw and washer

b - Jclamp
b
a
54852
90-8M0082471 JULY 2014 Page 2A-11

Ignition
Engine Control Module Installation

1. Secure the ECM to the cylinder block as shown.
2. Tighten the screws to the specified torque.
e d
f
c
d
c
a b a
54853
a- Washer (6)
b- Grommet (3)
c- Flange head screw (M6 x 25) (3)
d- Jclamp (1)
e- ECM
f- Cylinder block

ECM mounting screws 10 88.5
3. Install the CAN terminator resistor.
4. Install the engine harness connector onto the ECM.
5. Push the lock bar to secure the engine harness connector to the ECM.
6. Secure the power trim harnesses with the Jclamp.
a- CAN terminator resistor

b- Engine harness connector
c- Lock bar
d c d- Jclamp securing power trim harnesses
a
54851
Page 2A-12 90-8M0082471 JULY 2014

Ignition
Wire Color Code Abbreviations

Wire Color Abbreviations
BLK Black BLU Blue
BRN Brown GRY Gray
GRN Green ORN or ORG Orange
PNK Pink PPL or PUR Purple
RED Red TAN Tan
WHT White YEL Yellow
LT or LIT Light DK or DRK Dark
Main Power Relay (MPR)

Main Power Relay
The main power relay is located under the electrical cover on the front of the engine. The MPR is controlled by the ECM. The
main power relay supplies 12 volts to the fuel pumps, ignition coils, and the fuel injectors.
54892
Main Power Relay Test

The main power relay can be tested with the CDS G3 Diagnostic Interface tool.
90-8M0082471 JULY 2014 Page 2A-13

Ignition

8M0046124
Harness
f
d
c i
e
b h
18 34 51
1
67
a
68
69
70
33 50 66
17
j
k
48843
a- ECM connector
b- Main power relay
c- 15 amp fuse
d- ECM ground
e- Starter
f- Power stud
g- Battery ground (engine)
h- Neutral start safety switch (remote control or tiller handle)
i- Key switch
j- Engine harness to boat harness connector
k- Battery
Main Power Relay Removal

1. Disconnect the battery cables from the battery.
2. Press the engine harness relay connector tab and remove the relay connector from the relay. Do not pull on the wires.
3. Inspect the engine harness relay connector for damaged spade terminals or loose wires.
Page 2A-14 90-8M0082471 JULY 2014

Ignition
4. Cut the cable tie securing the power trim harnesses to the electrical plate.
a- Main power relay

b- Engine harness relay connector
c- Tab
a d- Power trim harness cable tie
c
b
54895
5. Use a small flat blade screwdriver to press the relay mounting tab.
6. Pull the relay toward the starboard side to remove it from the electrical plate.
d Typical relay and mounting base

a - Relay
b - Mounting base tab
c - Electrical plate
a d - Tab location
b
c 54896
Main Power Relay Resistance Test

NOTE: The relay can be tested for resistance without removing the relay from the electrical plate.
2. Perform a visual inspection of the main power relay spade terminals. Look for loose or corroded spade terminals. Use the
DMT 2004 digital multimeter for all of the following tests.

3. Measure the resistance between the main power relay coil terminal 85 (red/purple) and terminal 86 (yellow/purple).
Replace the relay if the resistance is not within the specifications.
87
87a
86 85
30
48220
Meter Test Leads

Meter Scale Reading
Red Black
Terminal 85 Terminal 86 Auto ohms 85 10
Main Power Relay Installation

1. Attach the main power relay to the mounting base on the electrical plate.
90-8M0082471 JULY 2014 Page 2A-15

Ignition
2. Push the engine harness relay connector into the main power relay until the tab is latched.
3. Secure the power trim harnesses to the electrical plate with a cable tie.
a- Main power relay

b- Engine harness relay connector
c- Tab
a d- Power trim harness cable tie
c
b
54895
4. Connect the battery cables to the battery.
Ignition Coil
Ignition Coils
The primary (+) side of the ignition coil receives battery voltage from the main power relay. When the key switch is turned "ON,"
the main power relay ground circuit is completed through the ECM. The main power relay transfers battery voltage to the two
coils. The coils are protected with a 20amp fuse. The negative side of the coil is connected to the engine ground through the
ECM. When this circuit is closed, a magnetic field is built up in the ignition coils. When the ECM is supplied with a trigger signal,
the ECM opens the circuit and the magnetic field collapses across the coil secondary winding, creating a high voltage charge
that is sent to the spark plugs.
Each coil supplies spark to two cylinders. The ignition system is a wasted spark design, where each coil fires once every
revolution.
54907
Ignition Coil Circuit Voltage Test

The ignition coils can be tested with the CDS G3 Diagnostic Interface tool.
Page 2A-16 90-8M0082471 JULY 2014

Ignition

8M0046124
Harness
a - Cylinder 1 and 4 coil

b - Cylinder 2 and 3 coil
c
c - Engine harness connector
a
c
b
54904
! WARNING
High voltage is present any time the key is turned on, especially when starting or operating the engine. Do not touch ignition
components or metal test probes and stay clear of spark plug leads when performing live tests.
1. Disconnect the engine harness connector from both of the coils.

2. Perform a visual inspection of the pins at the coil and the wires coming to the connector. Look for broken, bent, and
corroded pins at the coil; and loose, broken, or corroded wires at the connector.
3. Use the DMT 2004 digital multimeter to perform a voltage check of the wiring between the engine harness ignition coil
connector pin "B" (red/yel) and engine ground. Set the meter to DC volts.

4. Turn the ignition key to the "ON" position. Battery voltage will only be available when the main power relay is active.
NOTE: All 12 VDC power wires for the coils are spliced together. Unless all the coils have failed, the most likely failure
would be at the splice point, at the connector, or between the connector and the splice point.
90-8M0082471 JULY 2014 Page 2A-17

Ignition
Meter Test Leads

Meter Scale Reading
Red Black
Engine harness coil connector pin B Engine ground VDC Battery voltage
d e
c
b
RED/YEL
GRN/RED
1 18 34 51
67 a
C D
68
69
70
48926
17 33 50 66
a- ECM connector
b- Main power relay
c- 20 amp fuse
d- Ignition coil (cylinder 1 and 4)
e- Ignition coil (cylinder 2 and 3)
5. If battery voltage is not present on the red/yellow wire to the engine ground, there is an open circuit between the splice
point and the red/yellow wire connector.
Ignition Coil Resistance Test

1. Remove the electrical plate cover and the coil cover.
a - Electrical plate cover

b - Coil cover
a b
54913
Page 2A-18 90-8M0082471 JULY 2014

Ignition
2. Disconnect the engine harness connectors from the ignition coils.
3. Remove the spark plug leads from the ignition coil. Twist the ignition coil boot slightly while removing.
NOTE: Remove the ignition coil if necessary to perform the tests.
4. Use a DMT 2004 digital multimeter and perform the following tests.
c
a - Pin A
a b b - Pin B
c - Coil towers
42625
Ignition Coil Resistance Test

Between coil towers 72008800
Between pin A and B 0.30.5
Ignition Coil Installation

1. Apply Loctite Threadlocker 242 to the mounting screw threads.
2. Install the ignition coils onto the electrical plate.
4. Connect the engine harness connector to the ignition coils.
5. Connect the spark plug wires to the ignition coils.
6. Install the electrical plate cover and the coil cover.
a a - Screw (M6 x 25 flange head) (4)

b - Engine harness connector
b 1
54908

66 Loctite 242 Threadlocker Ignition coil mounting screw threads 92-809821

Screw (M6 x 25 flange head) (4) 10.2 90
90-8M0082471 JULY 2014 Page 2A-19

Ignition
Spark Plug Wire Resistance Test

Each spark plug wire should be measured for a specific range of resistance. The resistance should be measured from one end
to the other. Different meters may show different resistance numbers. A digital meter is more accurate than an analog meter.
Because there are many different manufacturers of meters, if the meter reads within 10% of the stated specifications, consider
the resistance within an acceptable range.
a - Coil tower end

b - Spark plug end
b
49262
Spark Plug Wire Resistance

Coil wire 1 and 4 16362101
Coil wire 2 13841792
Coil wire 3 12701652
Crankshaft Position Sensor (CPS)

The CPS is located at the top of the cylinder block next to the flywheel. The sensor contains a magnet that is positioned next to
the flywheel's lower ring gear. This ring gear has missing teeth at specific locations. The close proximity of the CPS magnet to
the teeth allows a magnetic field to be created each time a tooth passes the sensor. This field collapses and creates an AC
voltage pulse. This AC pulse is sent to the ECM. The timing and frequency of these pulses allows the ECM to regulate ignition
and fuel injector timing. If the crankshaft position sensor fails, the engine will run rough or stop running.
54910
Crankshaft Position Sensor Test

1. Perform a visual inspection of the sensor. The tip of the sensor must be flush across the end; if not, replace the sensor.
2. The tip of the sensor must be clean. There should be no metal debris (ring gear filings) attached to the sensor tip.
NOTE: There is a magnet mounted in the sensor's tip. If the magnet is missing, the sensor will not operate properly.
3. Inspect the flywheel timing wheel for:
Excessive corrosion
Square edges on the teeth
22 teeth with 2 teeth missing at specific locations
4. Replace the flywheel if it does not meet inspection requirements.
Page 2A-20 90-8M0082471 JULY 2014

Ignition
5. Disconnect the engine harness connector from the sensor and perform a visual inspection of the sensor pins and the wires
coming from the connector. Look for broken, bent, or corroded pins at the sensor; and loose, broken, or corroded wires at
the connector.
6. Use the DMT 2004 digital multimeter to measure the resistance across the crankshaft position sensor pins. Replace the
crankshaft position sensor if it is out of specification.
NOTE: If the engine problem occurs above 3000 RPM (runs rough, no high RPM), the resistance test of the crankshaft
position sensor may be good but the sensor can still be defective.
c d a- Magnet
b- CPS
c- Pin 1 (red)
d- Pin 2 (white)
a 17025
Crankshaft Position Sensor

Resistance at 21 C (70 F) 300350
7. Connect the harness to the crankshaft position sensor. Disconnect the 70 pin connector from the ECM and measure the
resistance between pins 13 and 14. The resistance must be within specification. If not, repair the wiring between the ECM
and the crankshaft position sensor.
18 34 51
1 a - ECM connector
67 a b - CPS
68
b
69
70 48981
17 33 50 66
Meter Test Leads Reading

Meter Scale
Red Black at 21 C (70 F)
Pin 13 Pin 14 Auto 300350
Crankshaft Position Sensor Removal

1. Remove the flywheel cover.
2. Cut the cable tie securing the crankshaft position sensor harness to the engine harness.
3. Disconnect the engine harness connector from the crankshaft position sensor.
90-8M0082471 JULY 2014 Page 2A-21

Ignition
4. Remove the two screws securing the crankshaft position sensor to the cylinder block.
a - Crankshaft position sensor

c d e
b - Screws securing the crankshaft
position sensor (2)
d - Engine water pressure sensor
(optional)
e - Cable tie
a
b
54917
Crankshaft Position Sensor Installation

1. Install the crankshaft position sensor onto the cylinder block and secure with two M5 x 13 screws. Tighten the screws to
2. Guide the connector under the engine water pressure sensor harness, if equipped.
3. Connect the engine harness connector to the crankshaft position sensor.
4. Secure the crankshaft position sensor to the engine harness with a cable tie.
a - Crankshaft position sensor

c d e
b - Screws securing the crankshaft
position sensor (2)
d - Engine water pressure sensor
(optional)
e - Cable tie
a
b
54917

CPS screw (M5 x 13) 5.1 45
5. Install the flywheel cover.
Page 2A-22 90-8M0082471 JULY 2014

Ignition
Throttle Position Sensor (TPS)

The TPS is located on the throttle body and is in direct contact with the throttle shaft. The TPS transmits throttle angle
information to the ECM, which regulates the fuel injector volume (pulse width) and ignition timing based on the throttle position
and signals from other cylinder block sensors. Should the sensor fail, a warning horn will sound and the ECM will reduce the
engine RPM. TPS settings are not adjustable. TPS settings can be monitored with the CDS G3 Diagnostic Interface tool
through the ECM. Voltage change should be smooth from idle to wideopen throttle. If the voltage change is erratic, the TPS is
defective.
b a- Throttle body
c b- Screen
c- Throttle position sensor
d- Engine harness connector
a
54919
Throttle Position Sensor Test

The throttle position sensor can be tested with the CDS G3 Diagnostic Interface tool.

8M0046124
Harness
1. Disconnect the engine harness from the TPS.

2. Perform a visual inspection of the throttle position sensor pins and the wires coming from the connector. Look for broken,
bent, or corroded pins at the throttle position sensor; and loose, broken, or corroded pins at the engine harness connector.
3. Disconnect the engine harness connector from the ECM.
4. Use the DMT 2004 digital multimeter to perform a resistance check of the wiring between the throttle position sensor
connector and the ECM connector.
NOTE: All sensor ground wires are spliced together and connect to the ECM at pin 42. Unless there are multiple sensor
failures, the most likely failure would be at the splice point, at the connector, or between the connector and the splice point.
b a- ECM connector
d b- Throttle position sensor
c- Purple/yellow
e d- Lt blue/white
c e- Black/orange
1 18 34 51 a
67
68
69
70 48929
17 33 50 66
90-8M0082471 JULY 2014 Page 2A-23

Ignition
Meter Test Leads

Meter Scale Reading
Red Black
Pin 42 Sensor connector A (black/orange) Auto Less than 1
Pin 53 Sensor connector C (Lt blue/white) Auto Less than 1
Pin 34 Sensor connector B (purple/yellow) Auto Less than 1
NOTE: Refer to Section 3C Throttle Body to remove and replace the TPS.
Cylinder Block Coolant Temperature Sensor

The cylinder block coolant temperature sensor is located near the thermostat housing. It is a thermistor immersed in the engine
coolant path. It supplies the ECM with engine temperature information. The ECM adjusts the timing and the amount of fuel
delivered according to the water temperature in the cylinder block. Low coolant temperature produces high resistance, while
high temperature causes low resistance.
54920
Cylinder Block Coolant Temperature Sensor Test

The CDS G3 Diagnostic Interface tool will help determine the proper functioning of the cylinder block coolant temperature
sensor by providing a numerical readout of the cylinder block coolant temperature before and after the engine is started. With
the engine not running, the engine block temperature should be approximately the same as the ambient air temperature. After
the engine is started, the temperature sensor should indicate a rise in cylinder block coolant temperature to approximately
6070 C (140158 F). Outside air temperature and the temperature of the water that the engine is operating in will directly
affect the engine block temperature.
1. With the engine running and the CDS G3 Diagnostic Interface tool connected to the engine, if the cylinder block coolant
temperature sensor does not appear to be indicating a temperature change, shake or move the sensor harness and
connector. If the temperature begins to change, look for a broken, loose, or corroded wire.

8M0046124
Harness
2. Disconnect the engine harness from the cylinder block coolant temperature sensor.
3. Perform a visual inspection of the cylinder block coolant temperature sensor pins and the wires coming from the connector.
Look for broken, bent, or corroded pins at the cylinder block coolant temperature sensor; and loose, broken, or corroded
wires at the connector.
Page 2A-24 90-8M0082471 JULY 2014

Ignition
4. The cylinder block coolant temperature sensor can be tested with an ohmmeter by removing the cylinder block coolant
temperature sensor from the cylinder block and heating or cooling the end of the cylinder block coolant temperature sensor
in a temperature controlled media. If the readings do not match those in the table, replace the cylinder block coolant
temperature sensor and retest.
b a - Pin A (black/orange)
b - Cylinder block coolant temperature sensor
c - Pin B (tan/black)
a c
16973
Meter Test Leads

Temperature Reading
Red Black
0 C 1.14 (32 F 2.1) 32.6 k
25 C 1.14 (77 F 2.1) 10.0 k
Pin B (tan/black) Pin A (black/orange)
50 C 1.50 (122 F 2.7) 3.6 k
100 C 2.36 (212 F 4.2) 678.0
5. If the resistance check indicates that the cylinder block coolant temperature sensor is serviceable, perform a resistance
check of the wiring between the cylinder block coolant temperature sensor connector and the ECM connector.
a
a - ECM connector
1 18 34 51
67
b - Cylinder block coolant
temperature sensor
21 b
68
BLK/ORN
TAN/BLK
69
42
70
66 48980
17 33 50
Meter Test Leads

Meter Scale Reading
Red Black
Pin 42 Sensor connector pin B (black/orange) Auto Less than 1
Pin 21 Sensor connector pin A (tan/black) Auto Less than 1
Cylinder Block Coolant Temperature Sensor Removal

2. Cut the cable tie securing the cylinder block coolant temperature sensor connector to the engine harness.
3. Disconnect the engine harness connector from the cylinder block coolant temperature sensor.
90-8M0082471 JULY 2014 Page 2A-25

Ignition
4. Remove the cylinder block coolant temperature sensor from the cylinder block.
a - Cylinder block coolant temperature

sensor
b a b - Connector
c - Cable tie securing the engine harness
c
connector and cylinder block coolant
temperature sensor
54931
Cylinder Block Coolant Temperature Sensor Installation

1. Install a new Oring onto the cylinder block coolant temperature sensor.
13384
2. Apply Loctite 567 PST Pipe Sealant onto the threads of the cylinder block coolant temperature sensor.

Loctite 567 PST Pipe
9 Cylinder block coolant temperature sensor threads 92-809822
Sealant
3. Install the cylinder block coolant temperature sensor into the cylinder block. Tighten the sensor to the specified torque.
4. Connect the engine harness to the cylinder block coolant temperature sensor.
5. Secure the cylinder block coolant temperature sensor connector and the crankshaft position sensor to the engine harness
with a cable tie.
a - Cylinder block coolant temperature

sensor
b a b - Connector
c - Cable tie securing the engine harness
c
connector and cylinder block coolant
temperature sensor
54931

Cylinder block coolant temperature sensor 15 132.7
Page 2A-26 90-8M0082471 JULY 2014

Ignition
Manifold Absolute Pressure (MAP) Sensor

The MAP sensor measures the changes in the intake manifold pressure. It is located on the intake manifold. When the ignition
key switch is turned to the "ON" position, the MAP sensor reads the ambient atmospheric pressure. This information is used by
the ECM as an indication of altitude. The MAP sensor signal will change as a result of engine load and speed changes. The
changing data is used to calculate air density and determine the engine's air mass flow rate, which in turn determines the
required fuel metering for optimum combustion.
54933
Manifold Absolute Pressure Sensor Test

The CDS G3 Diagnostic Interface tool will display the functioning of the MAP sensor by providing a numerical readout of the
sensor after the engine is started.
Manifold Absolute Pressure (MAP) Sensor Readings

At idle (neutral) 3440 kPa (4.95.8 psi)
At wideopen throttle 93.598.5 kPa (13.514.2 psi)
1. Start the engine and connect the CDS G3 Diagnostic Interface tool to the engine. If the MAP sensor does not appear to be
indicating a pressure change, shake or move the sensor harness and connector. If the pressure begins to change, look for
broken, loose, or corroded wires.

8M0046124
Harness
2. Turn the ignition key switch to the "OFF" position. Disconnect the engine harness from the MAP sensor.
3. Visually inspect the MAP sensor pins and the wires coming from the connector. Look for broken, bent, or corroded pins at
the MAP sensor; and loose, broken, or corroded wires at the connector.
4. Use the DMT 2004 digital multimeter to perform a resistance check between MAP sensor pins A, B, and C.
d a- Pin C (purple/yellow)
b- Pin A (black/orange)
c- Pin B (yellow)
d- MAP sensor
a b
c
23432
90-8M0082471 JULY 2014 Page 2A-27

Ignition

Meter Scale
Red Black At 21 C (70 F)
A B Auto 4.28 k 30%
A C Auto 6.48 k 30%
B A Auto 4.29 k 30%
B C Auto 6.48 k 30%
C A Auto 1.9 k 30%
C B Auto 6.8 k 30%
5. If the resistance check of the MAP sensor indicates that the MAP sensor is serviceable, perform a resistance check on the
wiring between the MAP sensor connector and the ECM connector.
a
1 18 34 51
67
68
b
69
S115
70
66 54932
17 33 50
a - ECM connector
b - MAP sensor
Meter Test Leads

Meter Scale Reading
Red Black
Pin 42 Sensor connector pin A (black/orange) Auto Less than 1
Pin 22 Sensor connector pin B (yellow) Auto Less than 1
Pin 34 Sensor connector pin C (purple/yellow) Auto Less than 1
Manifold Absolute Pressure Sensor Removal

1. Disconnect the engine harness from the MAP sensor.
2. Remove the screw securing the MAP sensor retaining bracket.
Page 2A-28 90-8M0082471 JULY 2014

Ignition
3. Pull the MAP sensor from the throttle body.
Shown with the intake manifold removed

a a - Engine harness
b - MAP sensor
c - Throttle body
d - Retaining bracket
e - Screw
e
d
b
c
54934
Manifold Absolute Pressure Sensor Installation

1. Push the MAP sensor into the intake manifold opening.
2. Install the MAP sensor retaining bracket into the intake throttle body.
3. Secure the retaining bracket with a screw. Tighten the screw to the specified torque.
4. Connect the engine harness to the MAP sensor.
a- Engine harness
a b- MAP sensor
c- Throttle body
d- Retaining bracket
e- Screw
e
d
b
c
54934

MAP sensor retaining bracket screw 1.7 15
Idle Air Control (IAC)

The IAC is located on the intake manifold. One side of the IAC is exposed to the ambient air pressures under the cowl. The
other side is exposed to the intake manifold pressures. The flow passage has a control orifice that is open or closed with the
stopper on the end of the IAC valve.
90-8M0082471 JULY 2014 Page 2A-29

Ignition
The IAC is normally open to allow ambient air pressure into the manifold for a barometric air pressure reading. When the IAC is
activated, the armature lifts, opening the orifice. During engine startup, manifold vacuum pressure (low pressure) causes the
stopper to close.
54947
Idle Air Control (IAC) Testing

The CDS G3 Diagnostic Interface tool will display the duty cycle of the IAC by providing a numerical percentage of the time the
IAC solenoid is active as a fraction of the total time under consideration.

8M0046124
Harness
1. Disconnect the engine harness from the IAC.

2. Disconnect the engine harness connector from the ECM.
3. Use the DMT 2004 digital multimeter to perform a resistance check on the engine harness between the IAC connector and
the ECM connection. Set the meter to read ohms, auto scale.
c
1 18 34 51 C12
WHT/LT BLU
RED/BLU
67 a A B
68
WHT/LT BLU
69 57 RED/BLU
S104
58 RED/BLU
70
17 33 50 66 54952
a- ECM connector
b- IAC
c- Main power relay
d- 20 amp fuse
Page 2A-30 90-8M0082471 JULY 2014

Ignition
Meter Test Leads

Meter Scale Reading
Red Black
Pin 3 IAC engine harness connector pin 1 (white/Lt blue) Auto Less than 1
Pin 57 or 58 IAC engine harness connector pin 2 (red/blue) Auto Less than 1

4. If the result of the test is not within specifications, check for corrosion or an open connection. Repair as needed.
IAC Removal
1. Disconnect the engine harness connector from the IAC.
2. Remove the two screws securing the IAC to the intake manifold.
3. Remove the IAC from the intake manifold.
a - Engine harness connector

b - Screws securing the IAC
a
54948
IAC Inspection and Installation

1. Inspect the IAC Orings for deformation or damage. Replace as required.
48198
2. Install the IAC onto the intake manifold and secure with two screws. Tighten the screws to the specified torque.
90-8M0082471 JULY 2014 Page 2A-31

Ignition
3. Connect the engine harness connector to the IAC.

b - Screws securing the IAC (M6 x 20 flange
a head)
54948

Screws securing the IAC (M6 x 20 flange head) 8 70.8
Manifold Air Temperature (MAT) Sensor

The MAT sensor is a thermistor that controls a signal voltage to the ECM. It is located on the intake manifold. It informs the
ECM of the air temperature inside the intake manifold. The ECM adjusts the fuel injection duration needed to run the engine at
optimum efficiency according to the MAT information. When the intake air is cold, the sensor resistance is high. As the air
temperature rises, resistance lowers.
54949
Manifold Air Temperature Sensor Test

The CDS G3 Diagnostic Interface tool will determine the proper functioning of the MAT sensor by providing a numerical readout
of the sensor temperature before and after the engine is started. With the engine not running, intake air temperature should be
approximately the same as the ambient air temperature with a cold engine. After the engine is started, the temperature sensor
should indicate a rise in air intake temperature. Outside air temperature will directly affect the engine manifold air intake
temperature.
1. Connect the CDS G3 Diagnostic Interface tool to the engine.
2. Start the engine. If the MAT sensor does not appear to be indicating a temperature change, shake or move the sensor
harness and connector. If the temperature begins to change, look for a broken, loose, or corroded wire.

8M0046124
Harness
3. Disconnect the engine harness from the MAT sensor.
4. Visually inspect the MAT sensor pins and the wires coming from the engine harness connector. Look for broken, bent, or
corroded pins at the MAT sensor; and loose, broken, or corroded wires at the engine harness connector.
5. Use the DMT 2004 digital multimeter to test the MAT sensor. Remove the MAT sensor from the intake manifold.
Page 2A-32 90-8M0082471 JULY 2014

Ignition
6. Immerse the MAT sensor into a temperature controlled media. If the readings do not match those in the table, replace the
MAT sensor and retest.
a - Pin A (tan)
b - Pin B (black/orange)
c - MAT sensor
c
b 17003
Meter Test Leads

Temperature Reading
Red Black
0 C (32 F) 6.5 k 5%
15 C (59 F) 3.2 k 5%
Pin A (tan) Pin B (black/orange)
25 C (77 F) 2.1 k 5%
100 C (212 F) 0.15 k 5%
7. If the resistance check of the MAT sensor indicates that the MAT sensor is serviceable, perform a resistance check of the
wiring between the sensor connector and the ECM connector.
a - ECM connector
b - MAT sensor
b
1 18 34 51
67 a
68
S116
69
70
17 33 50 66 54951
Meter Test Leads

Meter Scale Reading
Red Black
Pin 42 Sensor connector pin B (black/orange) Auto Less than 1
Pin 20 Sensor connector pin A (tan) Auto Less than 1
Manifold Air Temperature Sensor Removal

1. Cut the cable tie securing the engine harness to the MAT sensor.
2. Disconnect the engine harness connector from the MAT sensor.
90-8M0082471 JULY 2014 Page 2A-33

Ignition
3. Remove the two screws securing the MAT sensor to the intake manifold and remove the MAT sensor.
a - MAT sensor mounting screw (2)

b - Cable tie
b 54950
Manifold Air Temperature Sensor Installation

1. Install a new Oring onto the MAT sensor.
13378
2. Install the MAT sensor on the intake manifold. Tighten the MAT sensor mounting screws to the specified torque.
3. Connect the engine harness to the MAT sensor.
4. Secure the engine harness to the MAT sensor with a cable tie.
a - MAT sensor mounting screw (M4 x

16) (2)
b - Cable tie
b 54950

Screw (M4 x 16) 1.7 15
Page 2A-34 90-8M0082471 JULY 2014

Ignition
Oil Pressure Sensor

The oil pressure sensor measures the engine oil pressure. It is located on the starboard side of the cylinder block below the
starter. In the event of low oil pressure, the ECM will limit engine power based on the amount of oil pressure available at a
specific engine RPM.
54956
Oil Pressure Sensor Test

The CDS G3 Diagnostic Interface tool will help determine the proper functioning of the oil pressure sensor by providing a
numerical readout of the sensor after the engine is started.
1. Connect the CDS G3 Diagnostic Interface tool to the engine. If the oil pressure sensor does not appear to be indicating a
pressure change with the engine running at a normal operating temperature, shake or move the sensor harness and
connector. If the pressure begins to change, look for broken, loose, or corroded wires.

8M0046124
Harness
Oil Pressure Sensor

At idle RPM (oil cold to warm) 152303 kPa (2244 psi)
At WOT RPM (oil cold to warm) 372476 kPa (5469 psi)
At idle RPM (oil hot) 76152 kPa (1122 psi)
At WOT RPM (oil hot) 276373 kPa (4054 psi)
2. Disconnect the engine harness from the oil pressure sensor.
3. Visually inspect the pins of the oil pressure sensor and the wires coming from the engine harness connector. Look for
broken, bent, or corroded pins at the oil pressure sensor; and loose, broken, or corroded wires at the engine harness
connector.
4. Use the DMT 2004 digital multimeter to check the oil pressure sensor resistance between pins A, B, and C at 21 C
(70 F).
a- Pin A (black/orange)
d a b- Pin B (purple/yellow)
b
c- Pin C (Lt blue)
d- Oil pressure sensor
c
17006

Meter Scale
A B Auto 112.0 k 30%
90-8M0082471 JULY 2014 Page 2A-35

Ignition

Meter Scale
A C Auto 260.0 k 30%
B A Auto 112.0 k 30%
B C Auto 230.0 k 30%
C A Auto 260.0 k 30%
C B Auto 144.0 k 30%
5. If the resistance check of the oil pressure sensor indicates that the sensor is serviceable, perform a resistance check of the
sensor wiring between the sensor connector and the ECM connector.
1 18 34 51 c
67 a B b
A
68 C5
C
d
e
69
70
17 33 50 66 S115 S116 54958
a- ECM connector
b- Oil pressure sensor
c- Black/orange
d- Light blue
e- Purple/yellow
Meter Test Leads

Meter Scale Reading
Red Black
Pin 42 Sensor connector pin 1 (black/orange) Auto Less than 1
Pin 34 Sensor connector pin 2 (purple/yellow) Auto Less than 1
Pin 12 Sensor connector pin 3 (Lt blue) Auto Less than 1
Oil Pressure Sensor Removal

1. Disconnect the engine harness connector from the oil pressure sensor.
Page 2A-36 90-8M0082471 JULY 2014

Ignition
2. Remove the oil pressure sensor from the cylinder block.

a
54957
Oil Pressure Sensor Installation

1. Install a new Oring onto the oil pressure sensor.
13393
2. Apply Loctite 567 PST Pipe Sealant to the threads of the sensor.

9 Oil pressure sensor threads 92-809822
Sealant
3. Install the oil pressure sensor into the cylinder block. Tighten the sensor to the specified torque.
4. Connect the engine harness connector to the oil pressure sensor.

a
54957

Oil pressure sensor 15 132.7
Shift Position Sensor

The shift position sensor is mounted on the shift rail located on the starboard side of the engine. The shift position sensor is a
linear motion detector that is similar to the type of sensor used to determine the position of a throttle shaft. The shift position
sensor is preloaded to approximately the middle of the sensor travel, when it is installed on the shift rail and the drive unit is in
neutral.
Activation of the shift position sensor occurs with a cantilever actuator that is connected to the shift link. When the remote
control handle is moved to a gear position, the cantilever actuator that is connected to the shift link rotates the shift position
sensor. The linear motion of the shift position sensor is monitored by the ECM. The ECM determines a timing strategy based
on the general position and the direction of travel of the sensor.
90-8M0082471 JULY 2014 Page 2A-37

Ignition
The ECM is programmed to monitor relatively large windows of shift position. Each window is programmed into the ECM as a
specific number of counts. When the ECM reads the sensor position while at a specific count range, the spark timing will start
to fluctuate several degrees positive and negative to assist with removing the load on the shift clutch. This unloading of the shift
clutch facilitates an easy shift effort for the operator. While the shift position sensor is in the unload window count, the engine
may run slightly rough for a short time. Shifting with a normal smooth, quick effort, may not show any significant running
characteristic change.
Shift Position Sensor Test

The shift position sensor can be monitored for proper operation with the CDS G3 Diagnostic Interface tool.

8M0046124
Harness
1. Remove the starboard lower cowl. Refer to Section 5A Cowl Removal.

2. Disconnect the engine harness from the shift position sensor.
3. Perform a visual inspection of the shift position sensor pins and the wires coming from the connector. Look for broken,
bent, or corroded pins at the throttle position sensor; and loose, broken, or corroded pins at the engine harness connector.
4. Disconnect the engine harness 70 pin connector from the ECM.
5. Use the DMT 2004 digital multimeter to perform a resistance check of the wiring between the shift position sensor
b a- ECM connector
d b- Shift position sensor
c- Purple/yellow
c e d- Blue/yellow
e- Black/orange
1 18 34 51
67
a
68
69 S115
70
17 33 50 66 54946
Meter Test Leads

Meter Scale Reading
Red Black
Pin 54 Sensor connector C (blue/yellow) Auto Less than 1
Shift Position Sensor Removal

1. Remove the starboard lower cowl. Refer to Section 5A Cowl Removal.
2. Remove the shift bracket from the powerhead. Refer to Section 4A.
3. Disconnect the engine harness connector from the shift position sensor.
Page 2A-38 90-8M0082471 JULY 2014

Ignition
4. Remove the screw securing the shift position sensor to the shift rail and remove the shift position sensor.
a Bracket shown removed from powerhead

a - Shift bracket
b b - Cantilever actuator
c - Screw securing the shift position sensor
d - Shift position sensor
e - Engine harness connector
e
d
54953
Shift Position Sensor Installation

1. Install the tabs on the shift position sensor onto the slot in the cantilever actuator.
a - Shift bracket
b - Slot in the cantilever actuator
c - Tabs on the shift position
sensor
a b
54954
2. Rotate the cantilever actuator towards the front of the engine.

3. Align the tabs on the shift position sensor with the slot in the cantilever actuator and install onto the antirotation pin.
4. Secure the shift position sensor with a M4 x 13 screw. Tighten the screw to the specified torque.
90-8M0082471 JULY 2014 Page 2A-39

Ignition
5. Connect the engine harness connector to the shift position sensor.
e
d
54960 54955
a- Shift bracket
b- Cantilever actuator
c- Screw securing the shift position sensor
d- Shift bracket antirotation pin
e- Engine harness connector
6. Install the shift bracket onto the powerhead. Refer to Section 4A.
7. Install the starboard lower cowl. Refer to Section 5A Cowl Removal.
Page 2A-40 90-8M0082471 JULY 2014

Charging and Starting Systems
Electrical
Section 2B - Charging and Starting Systems
Table of Contents 2
B
Charging and Starting Specifications.................................2B-2 Stator Removal and Installation................................2B-14
Charging System Components.......................................... 2B-4 Voltage Regulator/Rectifier Removal and Installation
Starter Motor/Oil Filter/Sensors......................................... 2B-6 .............................................................................. 2B-16
Wire Color Code Abbreviations..........................................2B-8 Battery Charging System..........................................2B-17
Battery................................................................................2B-8 Troubleshooting the Battery Charging System......... 2B-18
Battery Cable Test...................................................... 2B-8 Alternator System Test............................................. 2B-19
Original Battery Cable Length and Gauge Shipped Stator Resistance Test............................................. 2B-20
with Engine..............................................................2B-9 Voltage Regulator/Rectifier Test...............................2B-20
Battery Cable Size for Outboard Models.................... 2B-9 Starter System................................................................. 2B-21
Replacement Parts................................................... 2B-11 Starter Motor Amp Draw........................................... 2B-21
Recommended Battery............................................. 2B-11 Starting System Description..................................... 2B-21
Charging a Discharged Battery.................................2B-11 Starting System Components................................... 2B-22
Winter Storage of Batteries.......................................2B-11 Starter Circuit Troubleshooting................................. 2B-22
Flywheel...........................................................................2B-12 Starter Removal........................................................2B-25
Flywheel Removal.................................................... 2B-12 Starter Installation.....................................................2B-26
Flywheel Installation................................................. 2B-13 Key Switch Test (Four Position)............................... 2B-28
Charging System/Stator...................................................2B-14
90-8M0082471 JULY 2014 Page 2B-1

Charging and Starting Specifications

Charging and Starting Specifications At 20 C (68 F)
Alternator typeStator under flywheel Three phase stator coil (18 pole)
Stator coil output
At 1000 RPM 23 A
At 5000 RPM 35 A
Stator coil outputPeak voltage
At 400 RPM (cranking) in neutralNo load 1218 V
Stator coil resistance 0.20.4
Rectifier regulator outputPeak voltage
Fuse 40 A
Starter type Positive engagement
Output 1.2 kW (12 V)
Rating 30 seconds
Reduction gear ratio 6:1
Ampere draw under load 130225 A
Ampere draw under no load 5070 A
Battery rating
For operation below 0 C (32 F) 1000 marine cranking amps (MCA) or 800 cold cranking amps (CCA)
Ampere hours (Ah) 65

Ground screw and the power stud nut
25 Liquid Neoprene 92- 25711 3
Starter solenoid power connections and ground wire connections
Stator mounting screw threads
66 Loctite 242 Threadlocker Voltage regulator/rectifier mounting screw threads and ground 92-809821
screw threads
Special Tools
CDS G3 Diagnostic Tool Kit 8M0087444
Provides diagnostic support for CDS G3. Includes CAN interface tool, CAN P
harness assembly, CAN H adaptor, CDS G3 CD, G3 harness adaptor and
instruction sheet.
41993
Page 2B-2 90-8M0082471 JULY 2014


14869
Flywheel Holding Tool 91 52344
Holds and/or turns the flywheel while making engine repairs, also used to torque
the flywheel or the engine coupler.
4738
Clampon Current Probe 91802650
Measures the current output of battery charging systems or current draw of

electric motors.
4006
H z TEMP
Measures RPM, ohms, amperes, AC and DC voltages; records maximums and
minimums simultaneously, and accurately reads in high RFI environments.
mA
A
V Hz
mV IG
OFF IP
TEMP
A mA COM V Hz
4516
12 Volt Shunt Tool 91889675A01
Connects to the 14pin engine harness. Turns on the ECM/PCM without the use
of the vessel engine control harness. Used for troubleshooting purpose only.
8036
90-8M0082471 JULY 2014 Page 2B-3

Charging System Components
2
3
7 9
8
10
56146
Page 2B-4 90-8M0082471 JULY 2014

Charging System Components

Torque
1 1 Flywheel cover
First 100 73.8
2 1 Screw (M20 x 168)
Final 190 140
3 1 Washer
4 1 Flywheel assembly
5 6 Screw (M6 x 30) 10 88.5
6 1 Stator assembly
7 1 Gasket
8 1 Voltage regulator/rectifier
9 1 Fuse holder with 40 amp fuse
10 6 Screw (M6 x 30) 10 88.5
90-8M0082471 JULY 2014 Page 2B-5

Starter Motor/Oil Filter/Sensors

2
11
14 13 10 10
15 13 12 10 10
16
17 18
19 20
4
6
8 55121
Page 2B-6 90-8M0082471 JULY 2014

Starter Motor/Oil Filter/Sensors

Torque
1 1 Crankshaft position sensor (CPS)
2 2 Screw (M5 x 13) 8 70.8
3 1 Oil drip tray
4 1 Plug
5 2 Screw
6 1 Fitting 40 29.5
7 1 Oil filter 20 177 14.8
8 1 Pressure sensor 15 132.7
9 1 Starter motor
10 6 Bushing
11 2 Spacer
12 1 Spacer
13 3 Washer
14 2 Screw (M8 x 80) 24 212 17.7
15 1 Screw (M8 x 45) 24 212 17.7
16 1 Screw (M8 x 20) 24 212 17.7
17 1 Screw (M6 x 13) 10 88.5
18 1 Lockwasher (M5)
19 1 Nut (M5) 2.5 22
20 1 Nut (M8) 24 212 17.7
90-8M0082471 JULY 2014 Page 2B-7


BLK Black BLU Blue
BRN Brown GRY Gray
RED Red TAN Tan
Battery
Battery Cable Test
This test is used to determine if there is excessive resistance in the battery's positive or negative cables, or if the cable is sized
properly to carry the necessary current needed to crank the engine at the proper RPM.
IMPORTANT: This test must be performed while the starter is cranking the engine. This engine starter is controlled by the
ECM. The starter can be engaged with the key switch or the CDS G3 diagnostic interface tool. Ignore any voltage readings
taken without the circuit under load.
! WARNING
Moving parts can cause serious injury or death. Wear eye protection and keep hands, hair, and clothing away from moving
parts when performing tests or checking adjustments on an operating engine.
1. Perform a load test on the battery following the instructions supplied with the load tester. Ensure the battery is brought to a
full charge after being tested.
2. Disconnect the fuel supply module fuel pump harness connector from the engine harness.
3. Connect a fuel pressure gauge to the Schrader valve on the fuel rail and release the fuel pressure into an appropriate
container. Ensure there is no spilled fuel while performing the following tests.
4. Engage the engine start process with the key switch or the CDS G3 diagnostic interface tool. While the starter spins the
engine over, measure the voltage across the battery posts, not the cable clamps. Record the voltage reading. If the voltage
is less than 10 VDC, replace the battery.
NOTE: The voltage reading in step 4 is the base voltage. The base voltage reading will be compared to the voltage
readings obtained in the following steps.
5. Wait 30 seconds and engage the engine start process with the key switch or the CDS G3 diagnostic interface tool. While
the starter spins the engine over, measure the voltage from the battery positive post (not the cable clamp) to the starter
post (the stud where the battery positive cable is connected). Record the voltage reading.
6. Wait 30 seconds and engage the engine start process with the key switch or the CDS G3 diagnostic interface tool. While
the starter spins the engine over, measure the voltage from the starter case to the battery negative post (not the cable
clamp). Record the voltage reading.
7. If the voltage reading in step 5 was more than 1.0 VDC different from the base voltage reading:
a. Check the cable connections for tightness and corrosion.
b. If the cable is tight and not corroded, replace the cable with a larger diameter cable.
8. If the voltage reading in step 6 was more than 1.0 VDC different from the base voltage reading:
a. Check the cable connections for tightness and corrosion.
b. If the cable is tight and not corroded, replace the cable with a larger diameter cable.
IMPORTANT: Resistance in the cables can cause a voltage drop and limit current to the starter. If corrosion is present, or if
the starter is worn, there may not be enough amperage to turn the starter motor.
NOTE: This engine is equipped with SmartStart circuitry. If the voltage at the starter is low, the engine control module
(ECM) prevents the starter motor from engaging.
9. Connect the FSM fuel pump harness connector to the engine harness.
Page 2B-8 90-8M0082471 JULY 2014

Original Battery Cable Length and Gauge Shipped with Engine

Original Equipment Battery Cable Length/Wire Gauge Size Shipped with Engine
Models (HP) Cable Length Wire Gauge Size
625 (2 and 4Stroke 400 cc [24.4 in] or less) 2.4 m (8 ft) 8
25115 (except OptiMax) 2.4 m (8 ft) 6
125250 (except OptiMax) 3.0 m (10 ft) 4
OptiMax/Verado 3.7 m (12 ft) 4
75/80/90/100/115 EFI FourStroke (2006 and newer) 3.7 m (12 ft) 4
Battery Cable Size for Outboard Models

IMPORTANT: Only use copper battery cables. Do not use aluminum cables for any outboard marine installations.
If longer battery cables are required, the wire gauge size must increase. See chart following for correct wire gauge size.
a a - Wire gauge size

b - Battery cable length
b
2758
90-8M0082471 JULY 2014 Page 2B-9

Copper Battery Cable Wire Gauge Size

Wire Gauge Size Number SAE
625 hp (2 and OptiMax, Verado, 75
25115 hp (except 125250 hp (except
Models 4Stroke 400 cc 115 EFI FourStroke
OptiMax) OptiMax)
[24.4 in] or less) (2006 and newer)
2.4 m (8 ft) 8 6
2.7 m (9 ft) 6 4
3.0 m (10 ft) 6 4 6
3.4 m (11 ft) 6 4 4
3.7 m (12 ft) 6 4 4 4
4.0 m (13 ft) 6 2 4 2
4.3 m (14 ft) 4 2 4 2
4.6 m (15 ft) 4 2 4 2
4.9 m (16 ft) 4 2 2 2
5.2 m (17 ft) 4 2 2 2
5.5 m (18 ft) 4 2 2 2
5.8 m (19 ft) 4 2 2 2
6.1 m (20 ft) 4 2 2 2
6.4 m (21 ft) 2 1 2 1
6.7 m (22 ft) 2 1 2 1
7.0 m (23 ft) 2 1 2 1
Cable Length 7.3 m (24 ft) 2 1 2 1
7.6 m (25 ft) 2 1 2 1
7.9 m (26 ft) 2 1/0 1 1/0
8.2 m (27 ft) 2 1/0 1 1/0
8.5 m (28 ft) 2 1/0 1 1/0
8.8 m (29 ft) 2 1/0 1 1/0
9.1 m (30 ft) 2 1/0 1 1/0
9.4 m (31 ft) 2 1/0 1 1/0
9.8 m (32 ft) 2 1/0 1 1/0
10.1 m (33 ft) 2 2/0 1/0 2/0
10.4 m (34 ft) 2 2/0 1/0 2/0
10.7 m (35 ft) 1 2/0 1/0 2/0
11.0 m (36 ft) 1 2/0 1/0 2/0
11.3 m (37 ft) 1 2/0 1/0 2/0
11.6 m (38 ft) 1 2/0 1/0 2/0
11.9 m (39 ft) 1 2/0 1/0 2/0
12.2 m (40 ft) 1 2/0 1/0 2/0
Page 2B-10 90-8M0082471 JULY 2014

Replacement Parts
! WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with
federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system
components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and
tighten all components.
IMPORTANT: Deepcycle batteries are not suitable for use as engine starting batteries or for use as accessory batteries that
are connected to high output engine charging systems. Deepcycle battery life may be shortened by high output engine
charging systems. Refer to individual battery manufacturer instructions for specific battery charging procedures and
applications.
Recommended Battery
A 12 volt marine battery with a minimum cold cranking amperage rating of 800 amperes or 1000 (minimum) marine cranking
amperes or 65 Ah (Amperes Hour) should be used.
Charging a Discharged Battery

! WARNING
An operating or charging battery produces gas that can ignite and explode, spraying out sulfuric acid, which can cause
severe burns. Ventilate the area around the battery and wear protective equipment when handling or servicing batteries.
The following basic rules apply to any battery charging situation:

1. Any battery may be charged at any rate (in amperes), or as long as spewing of electrolyte (from violent gassing) does not
occur, and for as long as electrolyte temperature does not exceed 52 C (125 F). If spewing of electrolyte occurs, or if
electrolyte temperature exceeds 52 C (125 F), charging rate (in amperes) must be reduced or temporarily halted to avoid
damage to the battery.
2. Battery is fully charged when, over a 2 hour period at a low charging rate (in amperes), all cells are gassing freely (not
spewing liquid electrolyte), and no change in specific gravity occurs. Full charge specific gravity is 1.2601.275, corrected
for electrolyte temperature with electrolyte level at 4.8 mm (3/16 in.) over plate, unless electrolyte loss has occurred (from
age or overfilling), in which case, specific gravity reading will be lower. For most satisfactory charging, lower charging rates
in amperes are recommended.
3. If, after prolonged charging, specific gravity of at least 1.230 on all cells cannot be reached, battery is not in optimum
condition and will not provide optimum performance; however, it may continue to provide additional service, if it has
performed satisfactorily in the past.
4. To check the battery voltage while cranking the engine with an electric starting motor at ambient air temperature of 23.8 C
(75 F), place the red (+) lead of the tester on the positive (+) battery terminal and the black () lead of the tester on the
negative () battery terminal. If the voltage drops below 101/2 volts while cranking, the battery is weak and should be
recharged or replaced.


90-8M0082471 JULY 2014 Page 2B-11

Flywheel
The flywheel is balanced to improve engine running characteristics. The flywheel is secured to the crankshaft by a screw (M20
x 168) (30 mm socket) and washer. The ring gear at the bottom of the flywheel is used with the starter motor to start the engine.
The flywheel has 22 teeth with 2 teeth missing at specific locations. As the teeth pass the crankshaft position sensor, an
electrical pulse is generated and sent to the engine control module (ECM). The frequency of these pulses in conjunction with
the missing tooth locations on the ring gear provides crankshaft location information to the ECM. The ECM will use this
information to regulate ignition and fuel injector timing.
The flywheel assembly contains 12 permanently charged ceramic magnets, spaced 30 apart, which are bonded into the inner
wall of the flywheel. The magnets alternate between north or south pole providing an 18 pole, three phase charging system.
Flywheel Removal
The flywheel has three threaded holes which are used with flywheel puller/lifting ring to remove the flywheel. These three holes
can also be used with the flywheel puller/lifting ring to remove or install the complete outboard on a boat.
IMPORTANT: Striking or heating the flywheel to ease removal will damage the flywheel. Do not strike or heat the flywheel.
a a - Flywheel cover
c b - Washer
b c - Flywheel screw (M20 x 168)
54991
2. Hold the flywheel with the flywheel holding tool. Loosen the flywheel screw four turns out from a light seat.
a - Breaker bar with M30 socket

b - Flywheel holding tool
54992

3. Install the flywheel puller base to the flywheel with three flange head screws. Tighten the screws to the specified torque.
4. Thread the flywheel puller adapter into the puller base until it bottoms out.
Page 2B-12 90-8M0082471 JULY 2014

5. Thread the flywheel puller screw into the flywheel puller adapter.
c d a- Flywheel puller base

b b- Flange head screw (3)
c- Flywheel puller adapter
a d- Flywheel puller screw
54993

Flange head screws (3) 27 20
6. Hold the flywheel with the flywheel holding tool.

7. Tighten the flywheel puller screw until the flywheel becomes loose.
8. Remove the flywheel puller.
9. Remove the M20 x 168 flywheel screw and washer.
10. Remove the flywheel.
Flywheel Installation
IMPORTANT: Clean flywheel/crankshaft taper with solvent and assemble dry.
1. Install the flywheel key into the crankshaft.
2. Align the flywheel with the key and install the flywheel onto the crankshaft.
Notice
Use care when installing the flywheel: The stator magnets will pull the flywheel down when positioning the flywheel onto
the crankshaft.
b a a - Crankshaft
b - Flywheel key
54994
90-8M0082471 JULY 2014 Page 2B-13

3. Secure the flywheel with the screw and washer. Use the flywheel holding tool to hold the flywheel and tighten the flywheel
screw in two stages to the specified torque.
a b
d
54999
a- Flywheel screw (M20 x 168)

b- Washer
c- Torque wrench and M30 socket
d- Flywheel holding tool

First 100 73.8
Flywheel screw (M20 x 168)
Final 190 140
Charging System/Stator
Stator Removal and Installation
Removal
1. Remove the flywheel. Refer to Flywheel Removal.
2. Remove the electrical plate cover and the coil cover.
a - Flywheel cover
a b - Electrical plate cover
c - Coil cover
c
55008
Page 2B-14 90-8M0082471 JULY 2014

3. Disconnect the stator harness from the voltage regulator/rectifer.
a - Stator harness
b - Connector
55007
4. Remove the six stator mounting screws. Remove the stator.
b a a - Stator
b - Stator mounting screws (6)
55000
Installation
1. Position the stator onto the top of the engine.
2. Apply Loctite 242 Threadlocker to the threads of the six stator mounting screws.
3. Secure the stator with the six stator mounting screws. Tighten the screws to the specified torque.
b a a - Stator
b - Stator mounting screws (M6 x 30 flange head) (6)
55000
90-8M0082471 JULY 2014 Page 2B-15


66 Loctite 242 Threadlocker Stator mounting screw threads 92-809821

Stator mounting screws (M6 x 30) (6) 10 88.5
4. Route the stator harness, as shown, and connect the stator harness to the voltage regulator/rectifer.
a - Stator harness
b - Connector
55007

6. Install the flywheel. Refer to Flywheel Installation.
Voltage Regulator/Rectifier Removal and Installation

Removal
1. Remove the battery cables from the battery.
2. Disconnect the voltage regulator/rectifier from the stator.
3. Remove the voltage regulator/rectifier black ground wire from the powerhead ground.
4. Remove the voltage regulator/rectifier red and red/white wires from the power stud.
5. Cut the three cable ties securing the harness to the powerhead.
6. Remove the fuse cover from the fuse holder.
7. Remove the six screws securing the voltage regulator/rectifier.
c a - Voltage regulator/rectifier
b - Mounting screw (M6 x 30
g flange head) (6)
g c - Fuse cover
d - Ground screw
e - Connector
a
f - Power stud
g - Cable tie
b
e
d
f
55018
Page 2B-16 90-8M0082471 JULY 2014

Installation
1. Apply Loctite 242 Threadlocker to the six voltage regulator/rectifier mounting screw threads.
2. Install the voltage regulator/rectifier and a new gasket onto the exhaust manifold.
3. Secure the voltage regulator/rectifier with six screws. Tighten the screws to the specified torque.
4. Route the harness as shown.
5. Connect the voltage regulator/rectifier to the stator.
6. Install the fuse holder into the fuse cover.
7. Secure the harness to the powerhead with three cable ties.
8. Apply Loctite 242 Threadlocker to the ground screw threads.
9. Secure the voltage regulator/rectifier black ground wire to the powerhead ground. Tighten the screw to the specified
torque.
10. Secure the voltage regulator/rectifier red and red/white wires to the power stud with an M8 nut and lockwasher. Tighten the
nut to the specified torque.
11. Apply Liquid Neoprene to the ground screw and power stud nut to prevent corrosion.
c a - Voltage regulator/rectifier
and new gasket
g b - Mounting screw (M6 x 30
g flange head) (6)
c - Fuse cover
d - Ground screw
a e - Connector
f - Power stud
g - Cable tie
b
e
d
f
55018

Voltage regulator/rectifier mounting screws (6) 10 88.5
Ground screw 10 88.5
First 2.8 25
Power stud nut
Final 17 150

Voltage regulator/rectifier mounting screw threads and
66 Loctite 242 Threadlocker 92-809821
ground screw threads
25 Liquid Neoprene Ground screw and the power stud nut 92- 25711 3
Battery Charging System

Description
The battery charging system components are the flywheel, stator, regulator/rectifier, and the battery. Alternating current (AC) is
generated in the stator assembly and flows to the regulator/rectifier which changes the AC to a regulated direct current (DC) for
charging the battery.
90-8M0082471 JULY 2014 Page 2B-17

Wiring Diagram
YEL/BLK
YEL/RED
a
YEL
f
BLK
BLK
YEL/RED BLK
b YEL
YEL/BLK
BLK
e
RED/WHT RED/WHT
RED RED
c d 54995
a- Stator
b- Voltage regulator/rectifier
c- 40amp fuse
d- Engine power stud
e- To battery positive terminal
f- To battery negative terminal
g- Starter solenoid
Flywheel
The flywheel assembly contains twelve permanently charged ceramic magnets, spaced 30 apart, which are bonded into the
inner wall of the flywheel. The magnets alternate between north or south pole providing an 18 pole, three phase charging
system.
Stator
The stator assembly, located under the flywheel, contains 18 "T" poles wound in series which provides three phase AC voltage
to the voltage regulator.
As the flywheel permanent magnets pass the stator windings, an AC current is produced at each winding as the magnet
polarity changes across them.
Battery
A 12 volt battery with a minimum rating of 1000 marine cranking amps (MCA) or 800 cold cranking amps (CCA) is
recommended. For operation below 0 C (32 F), a rating of 1000 marine cranking amps (MCA) or 900 cold cranking amps
(CCA) is recommended.
Voltage Regulator/Recifier
The voltage regulator is an electronic device that regulates alternator output according to the accessory loads and the charge
level of the battery. The voltage regulator manages the alternator output according to operating conditions. The voltage
regulator must balance the needs of a fully charged battery, long battery life, and accessory loads.
Symptoms of a faulty voltage regulator may include a discharged battery, short battery life, poor accessory and lighting
operation, frequent bulb replacement, lower than normal voltmeter readings, or frequent topping off of the battery's electrolyte.
Troubleshooting the Battery Charging System

IMPORTANT: The charging system may be damaged by:
Reversed battery cables
Running the engine with the battery cables disconnected and stator leads connected to the rectifier
An open circuit, such as a broken wire or loose connection
A fault in the battery charging system will cause the battery to become undercharged or overcharged. Check the battery
electrolyte level. Charge the battery, if necessary.
If the battery will not accept a satisfactory charge, replace the battery.
Page 2B-18 90-8M0082471 JULY 2014

If the battery accepts a satisfactory charge, determine the cause of the charging system problem as follows.
Ensure that the battery is fully charged.
Check for correct battery polarity: red cable to positive (+) battery terminal.
Check for loose or corroded battery cable connections.
Visually inspect the wiring between the stator and the battery for cuts, chafing, loose, corroded, or disconnected
connections.
Check for excessive electrical load from too many accessories.
Battery Charging System Test

Test Number Procedure Test Result Possible Cause/Remedy
1. Inspect the stator wires for
chaffing. A stator short to ground
results in high voltage.
Battery voltage above 15
2. Battery terminal loose or
V:
corroded.
3. Replace the voltage regulator/
rectifier.
Check the voltage of the 1. Charge the battery. If the battery
Test 1 starting battery while the cannot be satisfactorily charged,
engine is running. replace the battery.
Battery voltage below 2. Open fuse.
12.5 V:
3. Ground wire loose or open.
4. Battery cables loose or corroded.
5. Open stator connection.
Battery voltage 12.6 V to
Proceed to Test 2.
15 V:
Check the voltage of the Battery voltage below 10

Replace the battery.
starting battery while V:
Test 2
cranking the engine with the Battery voltage above 10
starter motor. Proceed to Test 3.
V:
Stator output current test The charging system is functioning
Perform the stator output is within specification: properly.
Test 3 current test. Refer to the
Alternator System Test. Stator output current test
Proceed to Test 4.
not within specification:
Stator resistance test is The charging system is functioning
Perform the stator within specification: properly.
Test 4 resistance test. Refer to the
Stator Resistance Test. Stator resistance test not
Replace the stator.
within specification:
Alternator System Test

IMPORTANT: The voltage regulator/rectifier must be functioning properly for accurate test results to be obtained.
1. Check the battery voltage at the battery with the engine running.
2. If the battery voltage is above 15 volts, replace the voltage regulator/rectifier. Check the condition of the battery as
overcharging may have damaged the battery.
3. If the battery voltage is below 12.5 volts, charge the battery. If the battery cannot be satisfactorily charged, replace the
battery.
4. If the battery accepts a satisfactory charge, check the battery voltage while cranking the engine. If cranking voltage is not
acceptable, replace the battery.
5. If cranking voltage is acceptable, install a clampon current probe around the red voltage regulator/rectifier wire.
Clampon Current Probe 91802650

6. Ensure the stator wires are secured away from the flywheel.
7. With engine running at the indicated RPM, the multimeter should indicate the following appropriate amps:
90-8M0082471 JULY 2014 Page 2B-19

Alternator output
At 1000 RPM 23 amps
At 5000 RPM 35 amps
8. A reading in excess of 35 amps at 5000 RPM and the battery at 12.6 volts indicates the charging system is functioning
properly.
9. If the ammeter reads less than the required amps at 5000 RPM, test the stator. Refer to Stator Resistance Test. If the
stator tests within specification, replace the voltage regulator/rectifier.
NOTE: The voltage regulator reduces the charging current as the battery voltage increases. Maximum current is produced
with the battery voltage at 12.6 volts.
Stator Resistance Test

NOTE: Resistance readings may vary slightly due to temperature changes. The test readings listed were taken at 20 C
(68 F).
1. With the engine turned off, disconnect the 3wire stator harness/voltage regulator/rectifier connector.
2. Use the DMT 2004 digital multimeter and perform the following test.
Test
YEL/RED
YEL/BLK
YEL
54998
Meter Test Leads

Meter Scale Reading
Red Black
Stator connector yellow lead Stator connector yellow/red lead 0.243
Stator connector yellow lead Stator connector yellow/black lead 0.243
Stator connector yellow/red lead Stator connector yellow/black lead 0.243
Each stator connector lead (yellow/red, yellow/black, or
Engine ground , OUCH, or OL
yellow)
Voltage Regulator/Rectifier Test

NOTE: Voltage regulator/rectifier specifications are given for informational purposes only. Use the appropriate troubleshooting
techniques previously mentioned to find the faulty component in the charging system.
1. Disconnect the 3wire stator harness/voltage regulator/rectifier connector.
2. Disconnect the voltage regulator/rectifier red and red/white wire ring terminal at the power stud.
3. Use the DMT 2004 digital multimeter. Set the meter to diode check and perform the following test.
Page 2B-20 90-8M0082471 JULY 2014

Test
a- Voltage regulator/rectifier
a b b- Stator connector
c- 40amp fuse
d- Power stud terminal
YEL/RED
YEL
YEL/BLK
YEL/RED e- Ground terminal
YEL/BLK
YEL
e d
BLK BLK
RED/WHT RED/WHT
RED RED
c
54997
Meter Test Leads

Meter Scale Reading
Red Black
Yellow/red Red Diode check 0.40.8 V
Yellow/black Red Diode check 0.40.8 V
Yellow Red Diode check 0.40.8 V
Red Yellow/red Diode check , OUCH, or OL
Red Yellow/black Diode check , OUCH, or OL
Red Yellow Diode check , OUCH, or OL
Yellow/red Black ground wire Diode check 1.5 V, , OUCH, or OL
Yellow/black Black ground wire Diode check 1.5 V, , OUCH, or OL
Yellow Black ground wire Diode check 1.5 V, , OUCH, or OL
Starter System
Starter Motor Amp Draw
Starter Motor
No load amp draw 5070 A
Normal amp draw 130225 A
Starting System Description

This engine has the SmartStart system, so the engine cranking and starting is controlled by the engine control module (ECM).
The starting system circuit is also controlled by the engine control module. The ECM monitors battery voltage and limits starter
motor cranking time to ensure that system components are protected and that the engine starts efficiently. The ECM will stop
the crank event if the engine does not start after eight seconds. The ECM will abort the crank event if there is no engine speed
detected (either a hydrolocked engine or the absence of a crank position signal) to avoid engine or damage to starting
components.
The battery supplies voltage to activate the starter motor from the starter solenoid. When the ignition key switch is turned to the
START position, the ECM completes the ground circuit for the start relay. The start relay becomes engaged, closes the switch
in the relay, and transfers fused 12 volts to energize the starter solenoid. The solenoid plunger closes the high current contacts,
transfers battery voltage to the starter motor brushes which enable the starter motor to rotate the engine to initiate the intake,
compression, combustion, and exhaust sequence. The starter motor, with a fully charged battery, is capable of rotating the
engine at 320 RPMs.
90-8M0082471 JULY 2014 Page 2B-21

There are two starter solenoid coil windings. The first starter solenoid coil winding pulls the starter solenoid plunger in,
engaging the gear/clutch assembly into the flywheel ring gear. The first coil winding may draw up to 30 amps at 12.6 volts when
activated. When the starter solenoid plunger is completely pulled into the starter solenoid, the first starter solenoid coil winding
is disconnected. The second starter solenoid coil winding is then activated to hold the starter solenoid plunger in, completing
the circuit to transfer battery voltage to the starter motor brushes. The second starter solenoid coil winding may draw up to 10
amps at 12.6 volts when activated.
The neutral start switch opens the key switch start circuit when the shift control lever is not in neutral, preventing accidental
starting when the engine is in gear. Engaging the starter circuit while the engine is running in neutral will turn the engine off.
Starting System Components

Battery
Ignition switch
Neutral start switch
Starter solenoid
Start relay
Starter motor
Main power relay
Fuses
Power stud
The engine control module (ECM) controls and monitors the starting system.
Starter Circuit Troubleshooting

Before Troubleshooting the Starter Circuit
Before troubleshooting the starter circuit, verify the following conditions:
1. Confirm that the battery is fully charged.
2. Ensure that the remote control lever is in neutral (if applicable).
3. Ensure that the tiller handle shift control is in neutral (if applicable).
4. Check all power and ground terminals for corrosion or loose connections.
5. Check all cables and wiring for frayed or worn insulation.
6. Check all of the fuses related to the operation of the engine.
IMPORTANT: The starting of this engine is controlled by the ECM. The main power relay and the starter relay should be
checked with the CDS G3 diagnostic interface tool prior to troubleshooting the starter, key switch, and harnesses. Use the
shunt tool to eliminate the boat harness and key switch when testing the main power relay and starter relay.

12 Volt Shunt Tool 91889675A01
Starter Circuit Troubleshooting Chart

Use the DMT 2004 digital multimeter or an equivalent auto range digital meter for all of the tests.
Some of the tests require the battery voltage be removed from the starter solenoid to prevent unexpected engine cranking.
The following starter circuit troubleshooting chart will assist in locating any malfunction in the starting circuitry. Do not skip any
of the testing sequence procedures unless advised to do so.
Page 2B-22 90-8M0082471 JULY 2014

NOTE: Numbers in a circle denote test points.

Numbers in a box denote the ECM connector pin position.
55011
6
j
k
3
l
1
5
h
2
7
8
g
f
d
e
c
m
b
67 68 69 70
34 66
34 50
18 33
1 17
a- ECM connector
b- Main power relay
c- Starter relay
d- 2amp fuse
e- 20amp fuse
f- 20amp fuse
90-8M0082471 JULY 2014 Page 2B-23

g- 15amp fuse
h- Starter solenoid
i- Power stud
j- Key switch
k- Neutral start switch (tiller handle or remote control)
l- 14pin connector
m- Battery
Starter Motor Does Not Turn

Test Number Procedure Test Results
Set the meter to read voltage, auto range. Battery voltage should be 12.6 V or higher. Battery voltage less
Measure the voltage between the starting than 12.6 V: check the condition of the battery and load test the
battery terminals. battery.
Voltage reading should be the same as the battery. Voltage
reading less than the battery:
Measure the battery voltage between test Ensure the battery positive and negative cables are the
point 1 (starter solenoid battery power cable) correct wire gauge for the cable length.
and test point 2 (common powerhead
ground). Ensure the battery cable connections are tight on the battery
and on the powerhead.
Test 1 Ensure the battery cables are not corroded.
Voltage reading should be the same as test point 1. Voltage
Measure the battery voltage between test reading less than test point 1:
point 3 (power stud) and test point 2 Ensure the nuts are torqued to specifications at test points 1
(common powerhead ground). and 3.
Ensure the cable connection is not corroded.
Measure the battery voltage between test Voltage reading should be the same as test point 1. Voltage
point 8 (ECM and engine sensor ground) and reading less than test point 1:
test point 1 (starter solenoid battery power Ensure the cable connection is not corroded.
cable). Ensure all fasteners are tight.
Disconnect the crankshaft position sensor for test 2. This will prevent the engine from starting and set a failure code. The code
should be erased with the CDS G3 diagnostic interface tool after the troubleshooting procedure is completed.
Battery voltage is indicated and the starter solenoid clicks. Check
the battery voltage at test point 1.
Battery voltage is greater than 9.5 V the starter motor is
Check for battery voltage at test point 4 defective.
between the starter solenoid yellow/red wire Battery voltage is less than 9.5 V the starter solenoid is
Test 2 terminal and test point 2 (common defective.
powerhead ground). Turn the key switch to
the START position. Battery voltage is indicated and the starter solenoid does not
click. Check the starter solenoid pull in coil resistance.
Refer to: Starter Will Not Stay Engaged (Chatter) Test 1.
No battery voltage indicated proceed to Test 3.
No continuity There is an open circuit between the battery
negative post and the common powerhead ground.
Set the meter to read ohms, auto scale.
Connect the meter at test point 2, between Check for a loose or corroded battery negative cable
Test 3 connection at the powerhead and the battery.
the common powerhead ground and the
battery negative post. Check for an open battery negative cable.
Continuity indicated proceed to Test 4.
Page 2B-24 90-8M0082471 JULY 2014

Starter Motor Does Not Turn

No continuity:
Key switch is failed or the harness has an open circuit.
Disconnect the key switch at test point 6 and test the key
switch ON circuit for continuity between the red and purple
Disconnect the 14pin connector at test point wires. No continuity: the key switch is failed. Continuity
5. Set the meter to read ohms, auto scale. indicated: Check the boat harness A and C pins for
Test 4 Connect the meter to pins A and C on the continuity. Replace or repair the boat harness if no continuity
boat harness 14pin connector, key switch is found.
end. Turn the key switch to the ON position.
Continuity indicated:
Turn the key switch to the START position. No continuity: the
key switch is failed.
Continuity indicated: proceed to Test 5.
No continuity:
The yellow/red wire is open: the neutral start switch is failed/
open or the key switch has failed.
Move the shift control in and out of gear: intermittent
continuity, the neutral safety switch is failed.
Connect the meter to pin C and pin N. Turn
Test 5 Disconnect the key switch at test point 6 and check for
the key switch to the START position.
continuity between the yellow/red wire and the purple wire on
the key switch. Turn the key switch to the START position:
no continuity, the key switch is failed.
Continuity indicated: Proceed to Starter Will Not Stay
Engaged (Chatter).
Starter Will Not Stay Engaged (Chatter)

IMPORTANT: Ensure that the battery is fully charged.
Starter solenoid holdin coil resistance is 0.4
10%.
Disconnect the yellow/red exciter wire from the starter solenoid
at test point 4. Remove the starter motor brush lead from the Starter solenoid holdin coil is good.
Test 1 starter solenoid at test point 7. Measure the resistance between Proceed to Test 2.
the exciter terminal of the starter solenoid and the starter Starter solenoid holdin coil resistance is in
solenoid metal housing. excess of 0.9 10% or open.
Starter solenoid holdin coil is defective.
Starter solenoid pullin coil resistance is 0.325
10%.
Remove the starter motor brush lead from the starter solenoid at Starter solenoid pullin coil is good.
test point 7. Measure the resistance between the exciter terminal Ensure battery is fully charged.
Test 2
of the starter solenoid and the starter solenoid brush lead
terminal. Starter solenoid pullin coil resistance is in
excess of 0.2 10% or open.
Starter solenoid pullin coil is defective.
Starter Removal
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected motor starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing motor components.
1. Disconnect the battery cables from the batteries.
90-8M0082471 JULY 2014 Page 2B-25

2. Remove the flywheel cover and the electrical plate cover.
a - Flywheel cover
b - Electrical plate cover
a
54961
3. Remove the screw securing the cylinder block ground wire onto the starter housing.
4. Remove the screw securing the battery negative cable onto the starter housing.
5. Pull the insulator boot off the starter solenoid power stud and remove the nut securing the battery cable to the starter
solenoid power stud. Remove the battery positive cable.
6. Remove the nut and washer securing the starter exciter wire to the starter solenoid. Remove the exciter wire.
7. Remove the three bolts securing the starter to the cylinder block.
b a- M8 x 45 flange head screw and washer

b- M8 x 80 flange head screw and washer (2)
c- Nut and washer securing the starter exciter wire
d- Nut securing the battery cable
e- Red insulator boot
c f- Screw securing the battery negative cable
d g- Screw securing the cylinder block ground wire
e
a
f
g 54962
Starter Installation
1. Install the starter onto the cylinder block and secure with two M8 x 80 and one M8 x 45 screw. Each screw must have a
washer. Tighten the screws to the specified torque.
2. Install the starter exciter wire to the starter solenoid and secure with a nut and washer. Tighten the nut to the specified
torque.
3. Install the battery positive cable to the starter solenoid power stud and secure with a nut. Tighten the nut to the specified
torque.
4. Apply Liquid Neoprene to the power connections to prevent corrosion and allow to dry.
5. Pull the insulator boot onto the starter solenoid power stud.
6. Secure the battery negative cable to the starter housing with a M8 x 20 screw. Tighten the screw to the specified torque.
7. Secure the cylinder block ground wire to the starter housing with a M6 x 25 screw. Tighten the screw to the specified
torque.
Page 2B-26 90-8M0082471 JULY 2014

8. Apply Liquid Neoprene to the ground wire connections to prevent corrosion.
a- Starter motor assembly

a b- Washer (3)
b
c- Screw (M8 x 80 flange head) (2)
c d- Screw (M8 x 45) flange head)
e- Screw (M8 x 20)
f- Screw (M6 x 13)
g- Lockwasher
h- Nut (M5)
i- Lock nut (M8)
d
e
f g
h
i 54965

Starter solenoid power connections and ground wire
connections

Screw (M8 x 80 flange head) 24 17.7
Screw (M8 x 45) 24 17.7
Screw (M8 x 20) 17 150.4
Screw (M6 x 13) 10 88.5
Nut (M5) 2.5 22
Locknut (M8) 9 79.6
b a- M8 x 45 flange head screw and washer

b- M8 x 80 flange head screw and washer (2)
c- Nut and washer securing the starter exciter wire
d- Nut securing the battery cable and cable to the power stud
e- Red insulator boot
c f- Screw securing the battery negative cable
d g- Screw securing the cylinder block ground wire
e
a
f
g 54962

M8 x 45 flange head screw, M8 x 80 flange head screw 24 17.7
Nut securing the starter exciter wire 2.5 22
Nut securing the battery cable to the starter 9 79.6
90-8M0082471 JULY 2014 Page 2B-27


Screw securing the battery negative cable (M8 x 20) 17 150.4
Screw securing the cylinder block ground wire (M6 x 25) 10 88.5
9. Connect the battery cables to the batteries.
10. Install the flywheel cover and the electrical plate cover.
a - Flywheel cover
b - Electrical plate cover
a
54961
Key Switch Test (Four Position)

1. Disconnect the key switch from the command module harness.
2. Set ohmmeter on R x 1 scale for the following tests.
3. If meter readings are other than specified in the following tests, verify that the switch and not the wiring is faulty. If the
wiring checks OK, replace the switch.
a- Pin A Red
b- Pin B Black
c- Pin C Purple/white
d- Pin D Purple
e- Pin E Black/yellow
f- Pin F Yellow/red
c b a
d e f 3887
Key Position Continuity should be indicated at the following points:

Off B E
Accessories A C
Run A D
A F
Start F D
A D
Page 2B-28 90-8M0082471 JULY 2014

Timing, Synchronizing, and Adjustments
Electrical
Section 2C - Timing, Synchronizing, and Adjustments
Table of Contents 2
C
Integrated Air Fuel Module and Fuel Rail Components.....2C-4 Throttle Link....................................................................... 2C-6
Idle Timing Adjustment (All Models).................................. 2C-6 Throttle Link Removal ................................................2C-6
Maximum Timing Adjustment (All Models)........................ 2C-6 Throttle Link Installation..............................................2C-7
90-8M0082471 JULY 2014 Page 2C-1


Throttle link actuator shoulder screw threads
Throttle lever shoulder screw threads
Shoulder of the throttle link actuator shoulder screw and washers
95 2-4-C with PTFE 92-802859A 1
Shoulder of the throttle lever shoulder screw and washers
Special Tools
instruction sheet.
41993
Page 2C-2 90-8M0082471 JULY 2014

Notes:
90-8M0082471 JULY 2014 Page 2C-3

Integrated Air Fuel Module and Fuel Rail Components

1
2
11 5
6
9
12
10
13
25
26
15 23
16
14
17 8
23
20
21
24
19 22
18
21 20 55125
17
Page 2C-4 90-8M0082471 JULY 2014


Torque
1 1 Screw (M4 x 10) 1.7 15
2 1 Manifold absolute pressure (MAP) sensor bracket
3 1 MAP sensor
4 4 Screw (M6 x 20) 8 70.8
5 1 Throttle body assembly
6 1 Throttle position sensor (TPS)
7 2 Screw (M4 x 16) 1.7 15
8 1 Intake manifold assembly
9 1 Gasket
10 4 Gasket
11 1 Throttle link assembly
12 10 Screw (M6 x 37 hex flange head) 10 88.5
13 1 Idle air control (IAC) valve
14 2 Screw (M6 x 20) 8 70.8
15 1 Throttle follower lever assembly
16 1 Swivel bushing
17 2 Shoulder bolt
18 1 Push nut
19 1 Retainer
20 2 Wave washer
21 2 Washer
22 1 Throttle cam assembly
23 2 Washer
24 1 Throttle cam return spring
25 1 Temperature sensor
26 2 Screw (M4 x 16) 1.7 15
90-8M0082471 JULY 2014 Page 2C-5

Idle Timing Adjustment (All Models)

Idle timing is not adjustable. Idle timing is controlled by the PCM/ECM. Idle timing can be monitored with the CDS G3
diagnostic interface tool.
Maximum Timing Adjustment (All Models)

Maximum timing is not adjustable. Maximum timing is controlled by the PCM/ECM. Maximum timing can be monitored with the
CDS G3 diagnostic interface tool.
Throttle Link
Throttle Link Removal
1. Remove the screw securing the throttle lever to the intake manifold.
e
b
a
f
d
c
56257
a- Shoulder screw
b- Wave washer
c- Washer
d- Throttle lever
e- Return spring
f- Washer
Page 2C-6 90-8M0082471 JULY 2014

2. Disconnect the throttle link from the throttle body lever.
56258
3. Remove the screw securing the throttle link actuator to the intake manifold.
4. Remove the throttle link rod actuator assembly from behind the intake manifold.
a- Shoulder screw
b- Wave washer
c
b c- Washer
a d- Throttle link actuator
e- Washer
d e
56259
Throttle Link Installation

1. Measure the link rod length. Adjust it if necessary.
a
48704
a - 336 mm (13.23 in.)
2. Install the throttle link rod onto the throttle link actuator.
3. Install the wave washer onto the throttle link actuator shoulder screw.
4. Install the washer onto the throttle link actuator shoulder screw.
5. Lubricate the washers and the shoulder of the screw with 24C with PTFE. Do not allow the lubricant onto the shoulder
screw threads.
6. Insert the shoulder screw with the washers through the throttle link actuator.
90-8M0082471 JULY 2014 Page 2C-7

7. Install the washer onto the shoulder screw threaded end.
a- Shoulder screw
b- Wave washer
c- Washer
f d- Throttle link actuator
e- Throttle link rod
f- Washer
d
e
c
b
56260
a

Shoulder of the throttle link actuator shoulder screw and
95 2-4-C with PTFE 92-802859A 1
washers
8. Apply Loctite 242 Threadlocker to the threads of the shoulder screw.

66 Loctite 242 Threadlocker Throttle link actuator shoulder screw threads 92-809821
9. Guide the throttle link rod behind the intake manifold and secure the throttle link actuator to the intake manifold. Tighten the
shoulder screw to the specified torque.
a - Throttle link rod

a b - Shoulder screw
56261

Shoulder screw 10 88.5
Page 2C-8 90-8M0082471 JULY 2014

10. Connect the throttle link to the throttle body lever.
56258
11. Install the return spring into the throttle lever.
a - Long end
b - Short end
a b
48210
12. Install the wave washer onto the throttle lever shoulder screw.
13. Install the washer onto the throttle lever shoulder screw.
screw threads.
15. Insert the shoulder screw with the washers through the throttle lever.
e a- Shoulder screw
b- Wave washer
c- Washer
d- Throttle lever
e- Washer
c d
b
56262
a

95 2-4-C with PTFE Shoulder of the throttle lever shoulder screw and washers 92-802859A 1
90-8M0082471 JULY 2014 Page 2C-9


66 Loctite 242 Threadlocker Throttle lever shoulder screw threads 92-809821
17. Verify the throttle actuator roller is engaged with the throttle lever.
18. Align the long end of the spring with the boss on the cylinder block.
19. Secure the throttle lever to the intake manifold block with the shoulder screw. Tighten the shoulder screw to the specified
torque.
a - Throttle actuator roller

b b - Long end of the spring
c - Shoulder screw
a
c
56263

Page 2C-10 90-8M0082471 JULY 2014

Accessory Wire Diagrams
Electrical
Section 2D - Accessory Wire Diagrams
Table of Contents 2
D
Wire Color Code Abbreviations......................................... 2D-2 Digital Speedometer Harness Test....................................2D-5
Boat Sensor....................................................................... 2D-2 Digital Block Water Pressure Sensor Installation.............. 2D-6
Boat Sensor Harness Test......................................... 2D-2 Digital Block Water Pressure Harness Test.......................2D-7
SmartCraft Pitot Sensor Installation...................................2D-3
90-8M0082471 JULY 2014 Page 2D-1

Special Tools

V Hz
H z TEMP
mA
A
mV IG
OFF IP
TEMP
A mA COM V Hz
4516

BLK Black BLU Blue
BRN Brown GRY Gray
RED Red TAN Tan
Boat Sensor
The boat sensor harness connector is a junction location for sensors external of the engine operations. These external sensors
may include: depth, paddle wheel for low speeds, seawater temperature, fuel, and water levels and is most useful when
incorporating SmartCraft gauges, GPS, and chart plotter technologies.
Boat Sensor Harness Test

1. Disconnect the vessel harness from the engine harness boat sensor connector.
2. Perform a visual inspection of the engine harness boat sensor connector pins and the wires coming from the connector.
Look for broken, bent, or corroded pins.
3. Disconnect the engine harness from the ECM.
4. Use the DMT 2004 digital multimeter to perform an ohm check of the wiring between the engine harness boat sensor
Page 2D-2 90-8M0082471 JULY 2014

NOTE: All accessory sensor ground wires are 5 volts negative. They are spliced together and connect to the ECM at pin
10. All accessory sensor power wires are 5 volts positive. They are spliced together and connect to the ECM at pin 51.
Unless there are multiple sensor failures, the most likely failure would be at the splice point, connector, or between the
connector and the splice point.
a
1 18 34 51
67
68
GRY/DK BLU
b
69
70
17 33 50 66
48967
a - ECM connector
b - Boat sensor connector
Meter Test Leads

Meter Scale Reading ()
Red Black
Pin 7 Sensor connector C (tan/purple) Auto Less than 1
Pin 10 Sensor connector A (black/green) Auto Less than 1
Pin 15 Sensor connector D (gray/dark blue) Auto Less than 1
Pin 38 Sensor connector E (tan/orange) Auto Less than 1
Pin 40 Sensor connector F (pink/black) Auto Less than 1
Pin 51 Sensor connector B (purple/black) Auto Less than 1
SmartCraft Pitot Sensor Installation

1. Push the adapter fitting into the Legris straight fitting. Ensure that the conduit clip is secured around the pressure sensor.
c a- Adapter fitting
a d b- Legris straight fitting
b c- Conduit clip
d- Pressure sensor
48523
90-8M0082471 JULY 2014 Page 2D-3

2. Attach the short end of the ECU bracket to the lower right corner of the ECU using the existing mounting hardware. Ensure
that the washer is between the bracket and the grommet.
a - ECU
a b - ECU bracket (provided)
c - Washer (reuse)
55235
3. Tighten the screw to the specified torque.

ECU mounting screw 10 88.5
4. Locate the engine harness connector for the SmartCraft pitot sensor and remove the cap.
55261
Connector shown with cap removed
5. Connect the engine harness connector to the SmartCraft pitot sensor.

6. Route the speedometer hose towards the adapter fitting and cut the hose to an appropriate length. To ensure that the hose
does not interfere with the shift linkage, be certain to route the hose around the outside of the cables, as shown.
55288
Route the speedometer hose around the outside of cables
7. Push the speedometer hose onto the fitting.
Page 2D-4 90-8M0082471 JULY 2014

8. Insert the conduit clip into the hole in the long end of the ECU bracket.
b Pitot sensor mounted to ECU

a - Speedometer hose
b - ECU bracket
a
c
55236
Digital Speedometer Harness Test

The digital speedometer sensor harness connector is used to connect a digital water pressure (speed) sensor. The digital
speedometer sensor is required when incorporating SmartCraft gauges, GPS, and chartplotter technologies.
1. Disconnect the speedometer sensor harness from the engine harness digital speedometer sensor connector.
2. Perform a visual inspection of the engine harness digital speedometer sensor connector pins and the wires coming from
the connector. Look for broken, bent, or corroded pins.
NOTE: All accessory sensor ground wires are 5 volts negative. They are spliced together and connect to the ECM at pin
10. All accessory sensor power wires are 5 volts positive. They are spliced together and connect to the ECM at pin 51.
Unless there are multiple sensor failures, the most likely failure would be at the splice point, connector, or between the
connector and the splice point.
d a- ECM connector
b- Speedometer sensor connector
c- Pin A (black/green)
c d- Pin C (white/orange)
e e- Pin B (purple/black)
b
B
C
A
1 18 34 51
67
a
68
69
70
66 56236
17 33 50
90-8M0082471 JULY 2014 Page 2D-5

Meter Test Leads

Red Black
Pin 10 Sensor connector A (black/green) Auto Less than 1
Pin 36 Sensor connector C (white/orange) Auto Less than 1
Pin 51 Sensor connector B (purple/black) Auto Less than 1
Digital Block Water Pressure Sensor Installation

1. Remove the top cowl assembly.
54757
3. Locate the engine harness connector for the water pressure sensor and remove the cap and cable tie.
4. Use a 4 mm hex bit socket to remove the plug. It may be necessary to gently strike the plug with an appropriate punch to
loosen it before removal.
a a - Connector cap
b - Cable tie
c - Plug
b
c
54758
5. Thread the water pressure sensor into the cylinder head. Tighten the sensor securely. Ensure the lock release is
accessible.
Page 2D-6 90-8M0082471 JULY 2014

6. Connect the engine harness connector to the water pressure sensor.
54756
Water pressure sensor
7. Secure the sensor harness with a new cable tie.

9. Install the top cowl assembly.
Digital Block Water Pressure Harness Test

The digital block water pressure sensor harness connector is used to connect a digital block water pressure sensor. The digital
block water pressure sensor is most useful when incorporating SmartCraft gauges or other technologies that use a control area
network (CAN) communications protocol.
54756
Digital block water pressure sensor
1. Disconnect the digital block water pressure sensor from the engine harness digital block water pressure sensor connector.
2. Perform a visual inspection of the engine harness digital block water pressure sensor connector pins and the wires coming
from the connector. Look for broken, bent, or corroded pins.
90-8M0082471 JULY 2014 Page 2D-7

NOTE: All engine sensor ground wires are 5 volts negative. They are spliced together and connect to the ECM at pin 42.
All accessory sensor power wires are 5 volts positive. They are spliced together and connect to the ECM at pin 34. Unless
there are multiple sensor failures, the most likely failure would be at the splice point, connector, or between the connector
and the splice point.
d a - ECM connector
b - Digital block water pressure sensor
connector
c - Pin A (black/orange)
e d - Pin C (white/green)
c e - Pin B (purple/yellow)
b
1 18 34 51 a
67 B A C
68
69
70
17 33 50 66
56203
Meter Test Leads

Red Black
Pin 35 Sensor connector C (white/green) Auto Less than 1
Page 2D-8 90-8M0082471 JULY 2014

Fault List
Electrical
Section 2E - Fault List
Table of Contents 2
E
Fault List............................................................................ 2E-2
90-8M0082471 JULY 2014 Page 2E-1

Fault List
Special Tools
harness assembly, CAN H adapter, CDS G3 CD, G3 harness adapter and
instruction sheet.
41993
Fault List
Refer to the following table for an explanation of faults and possible solutions when using the CDS G3 diagnostic interface tool.
Time for
Warning Horn Guardian
Fault Name Fault Explanation Possible Root Cause Fault to
Type Response
Trigger
Baro Barometer reading Bad MAP sensor or sensor
No horn 1 second 100%
Range out of specification circuit
Engine is running
Possible thermostat failure
Cold_ below specified
No horn from excessive debris or 8 minutes 100%
Engine running temperature
corrosion
for 8 minutes
Fault is calibrated to
DRVP Critical Alternator sense lead shorted Based on voltage
trigger fault at 15 V 10 seconds
InputHigh 6 second beep or bad alternator power limit table
or 550 ADC
Bad battery connections, weak
DRVP Critical Based on voltage
Low battery voltage battery, too much electrical 17 seconds
InputLow 6 second beep power limit table
load, failed alternator
ECTInput Noncritical ECT circuit has failed
Possible sensor or wire failure 10 seconds 100%
High 6 beeps electrically open
ECTInput Noncritical ECT circuit has failed Possible sensor or wire failure
10 seconds 100%
Low 6 beeps electrically shorted to ground
ECT circuit
Water pump failure, debris in 10%Based on
ECT_ Critical exceeded maximum
cooling system, or failed 15 seconds temperature
Overtemp 6 second beep allowable operating
thermostat power limit table
temperature
EST1_ Ignition circuit failed
Noncritical Ignition coil, wire harness, or
Output open while the 15 seconds 100%
6 beeps ECM failure
Fault engine was running
EST2_ Ignition circuit failed
Noncritical Ignition coil, wire harness, or
Output open while the 22 seconds 100%
6 beeps ECM failure
Fault engine was running
ESTOP_ ESTOP was Lanyard is pulled, failed switch, Engine is not
No horn 3 seconds
Active activated or harness running
Encoder Failure to the sensor or wire
Fault harness. Could also be a poor
Critical Crankshaft position
Crank connection that is creating too 1 second 100%
6 second beep sensor circuit failure
Cam much resistance/load on the
Trigger circuit.
FuelPump Current draw from Contamination in the electric
Critical
Current the fuel pumps is fuel pumps or failure of the 1 second 100%
6 second beep
High over specification pumps
Page 2E-2 90-8M0082471 JULY 2014

Fault List
Time for
Type Response
Trigger
FuelPump Current draw from Fuel pump circuit has failed
Critical
Current the fuel pumps is open due to a bad harness or 1 second 100%
6 second beep
Low below specification pump
20%based on
Guardian_
the Guardian
Active_ No horn Refer to active fault Refer to active fault 1 second
level set by the
Fault
active fault
Power limited
Guardian_ Oil pressure is below
Noncritical Low on oil, bad oil pump, or based on the oil
Oil specification for 1 second
6 beeps pressure relief valve pressure power
Pressure engine's speed
limit table.
Engine is running The power limit is
Failed water pump, thermostat,
Guardian_ Noncritical above specified based on the
or debris causing water 1 second
Overheat 6 beeps overheat overtemp power
restrictions
temperature limit table
Guardian_
Maximum RPM
Over No horn Engine is incorrectly propped 1 second 100%
exceeded
speed
Battery voltage is out
of specification. This Limited based on
Guardian_ Critical See DRVP low or high fault
fault should 1 second the battery power
Voltage No horn explanations
accompany DRVP limit table
low or high.
HORN_
Noncritical ECM sensed the Horn is disconnected or bad
Output 15 seconds 100%
No horn horn circuit is open wire harness
Fault
Intake air Failed intake air temperature
IATInput Noncritical
temperature circuit is sensor or open in the wire 9 seconds 100%
High 6 beeps
electrically open harness
Intake air Failed intake air temperature
IATInput Noncritical
temperature circuit is sensor or short in the wire 9 seconds 100%
Low 6 beeps
electrically shorted harness
INJ1_
Noncritical Shorted injector 1
Output Failed injector or wire harness 10 seconds 100%
6 beeps circuit
Fault
INJ2_
6 beeps circuit
Fault
INJ3_
6 beeps circuit
Fault
INJ4_ Noncritical Shorted injector 4
Failed injector or wire harness 10 seconds 100%
OutputFault 6 beeps circuit
If the crank request signal is 2
Detects if a key
KeySw_ Noncritical V lower than the wake input
switch has a faulty 1 second 100%
Dirty 6 beeps into the PCM the fault will
crank terminal
become active
If the key is turned on (not
Detects if there is
cranking) and the voltage on
current leaking from
KeySw_ Noncritical the crank request line is
the power terminal of 5 seconds 100%
Leaky 6 beeps between 3 V and 9.5 V (crank
the key switch to the
request threshold) the fault will
crank terminal
be activated
90-8M0082471 JULY 2014 Page 2E-3

Fault List
Time for
Type Response
Trigger
IAC circuit has
LIAC_
Noncritical experienced an open IAC has electrically failed, wire
Output 5 seconds 100%
6 beeps or short electrical harness is open or shorted
Fault
failure
Airflow calculation
MAF_ Noncritical Throttle restrictor has been
too high (75 hp 10 seconds 50%
Too_High 6 beeps removed
model only)
MAP circuit is
MAPInput Noncritical electrically shorting Internally shorted sensor or
1 second 100%
High 6 beeps the sense lead to 5 V harness
power
MAP circuit has 0 V MAP sensor is open, engine
MAPInput Noncritical
present on the sense harness has an open, or 5 V 1 second 100%
Low 6 beeps
lead sensor power is 0.
Fault only occurs at
MAPR_ 100% fault clears
Noncritical idle. MAP must be
TPS1 Failed MAP sensor 10 seconds when the engine
6 beeps greater than baro
Rationality comes off of idle
pressure.
Plugged MAP
MAP_ Noncritical sensor, faulty
5 seconds 100%
Rationality 6 beeps connection, or
sensor
Neutral_ Engine RPM Engine running in neutral
Over No horn exceeds the neutral above 2500 RPM, or bad shift 1 seconds 100%
speed overspeed setting position sensor
5% based on
Engine running with Bad oil pressure sensor/switch,
OilPress_ Critical engine oil
oil pressure below low engine oil pressure, failed 15 seconds
Low 6 second beep pressure power
calibration set points oil pump, oil dilution
limit map
Oil
Pressure Noncritical Oil pressure sense Failed sensor or engine
5 seconds 100%
Input 6 beeps lead has 5 V present harness
High
Oil
Pressure Noncritical Oil pressure sensor Failed oil pressure sensor or
5 seconds 100%
Input 6 beeps has an open circuit engine harness
Low
Troll control cannot
RxDoc2_ Noncritical Boat harness failed open or
detect the controlling 11 seconds 100%
SOH 6 beeps gauge failure
gauge or device
STRT_ Faulty engine
Critical Engine is not
Output harness, solenoid, 1 second
6 second beep running
Fault or switch
Security Theft
Security_ Theft Deterrent System
Critical Deterrent System
Device_ harness disconnected, failed 30 seconds
6 beeps error or component
Missing open, or module failure
missing
The engine has been No key fob or the incorrect key
Security_ Noncritical
started without fob is installed. Possible open 10 seconds 20%
Locked 6 beeps
recognizing a key fob in the harness.
Page 2E-4 90-8M0082471 JULY 2014

Fault List
Time for
Type Response
Trigger
Theft Deterrent
System installed but
Security_ Noncritical The set up procedure was not
not correctly 5 seconds 20%
Setup 6 beeps correctly followed
recognized by the
system
ShiftPos Shift position sensor
Noncritical Shorted sensor, engine
Input has 5 V present on 6 seconds 100%
6 beeps harness, or ECM
High the sense lead
ShiftPos Shift position sensor Failed sensor,
Noncritical
Input has 0 V present on ECM or open in the engine 6 seconds 100%
6 beeps
Low the sense lead harness
Shift_ Noncritical
Shift position sensor 4 seconds 100%
Potentiometer 6 beeps
TPS1_ Noncritical TPS as 5 V present Shorted TPS or engine
2 seconds
RangeHigh 6 beeps on the sense lead harness
Failed TPS, open engine
TPS1_ Noncritical TPS has 0 V present
harness, or 0 volts on sensor 2 seconds 100%
RangeLow 6 beeps on the sense lead
power
TPS voltage is out of
The throttle is moved prior to
Noncritical specified range when 2 seconds
TPS_AdaptMech turning the key on, or the TPS 100%
6 beeps the key switch is and 10 starts
has been tampered with
turned on
TPS value falls
below mininum
Noncritical
TPS_Rationality specification while Bad TPS or linkage problem 3 seconds 100%
6 beeps
running at or above
the RPM threshold
WaterInFuel Noncritical Water in fuel has 0 V Water is present in filter, failed
5 seconds 100%
InputLow 6 beeps on the sense lead sensor, or harness
Sensor power
Critical
XDRPaInputHigh (XDRPa) is above Failed ECM 1 second 100%
6 second beep
specification
Sensor power
Shorted out sensor power due
Critical (XDRPa) is below
XDRPaInputLow possibly from bad 3 wire 1 second 5%
6 second beep specification this is
sensor, harness, or ECM
engine sensor power
Sensor power
Noncritical (XDRPb) is above
XDRPbInputHigh Failed ECM 1 second 100%
6 beeps specification this is
boat sensor power
Sensor power
Shorted out sensor power due
Noncritical (XDRPb) is below
XDRPbInputLow possibly from bad 3 wire 1 second 100%
6 beeps specification this is
sensor, harness, or ECM
boat sensor power
90-8M0082471 JULY 2014 Page 2E-5

Fault List
Notes:
Page 2E-6 90-8M0082471 JULY 2014

Theory of Operation
Fuel Systems
Section 3A - Theory of Operation
Table of Contents
3
Integrated Air Fuel Module and Fuel Rail Components..... 3A-4 Idle Air Control (IAC) Valve.......................................3A-10
Fuel Supply Module (FSM) Components ..........................3A-6 Fuel Supply Module (FSM)....................................... 3A-10
Air Induction System.......................................................... 3A-8 Fuel Lift Pump...........................................................3A-11
Fuel Injection System.........................................................3A-8
Air Induction and Fuel Injection System.............................3A-8
HighPressure Fuel Pump........................................ 3A-12
Fuel Pressure Regulator...........................................3A-12
A
Fuel System Description.............................................3A-8 Inline Fuel Filter....................................................... 3A-13
Main Power Relay (MPR)........................................... 3A-9 Fuel Injector.............................................................. 3A-13
Intake Manifold........................................................... 3A-9 Guardian Protection System............................................ 3A-13
Engine Control Module (ECM)....................................3A-9 Fuel Flow Diagram...........................................................3A-14
Throttle Body.............................................................. 3A-9
90-8M0082471 JULY 2014 Page 3A-1

Theory of Operation
Special Tools
instruction sheet.
41993
Page 3A-2 90-8M0082471 JULY 2014

Theory of Operation
Notes:
90-8M0082471 JULY 2014 Page 3A-3

Theory of Operation

1
2
11 5
6
9
12
10
13
25
26
15 23
16
14
17 8
23
20
21
24
19 22
18
21 20 55125
17
Page 3A-4 90-8M0082471 JULY 2014

Theory of Operation

Torque
1 1 Screw (M4 x 10) 1.7 15
3 1 MAP sensor
4 4 Screw (M6 x 20) 8 70.8
7 2 Screw (M4 x 16) 1.7 15
9 1 Gasket
10 4 Gasket
14 2 Screw (M6 x 20) 8 70.8
16 1 Swivel bushing
17 2 Shoulder bolt
18 1 Push nut
19 1 Retainer
20 2 Wave washer
21 2 Washer
23 2 Washer
26 2 Screw (M4 x 16) 1.7 15
90-8M0082471 JULY 2014 Page 3A-5

Theory of Operation
Fuel Supply Module (FSM) Components

1
2
20
22
21
13
3
23 14
15
4
7 5
13
6 8 16
9
17
10
7 16
12
18
11
7
10 19
48372
Page 3A-6 90-8M0082471 JULY 2014

Theory of Operation
Fuel Supply Module (FSM) Components

Torque
1 4 Screw 10 88.5
2 1 FSM top housing
3 1 Oring
4 1 Regulator assembly
5 1 Oring
6 1 Oring
7 3 Seal
8 2 Oring
9 1 FSM cap
10 2 Seal
11 1 Lowpressure pump assembly
12 1 Highpressure pump assembly
13 4 Oring
14 2 Fuel tube
15 1 Suction tube
16 4 Oring
17 2 Water tube
18 1 Seal
19 1 FSM bottom housing
20 1 Electrical harness assembly
21 1 Oring
22 1 Oring
23 1 Spacer
90-8M0082471 JULY 2014 Page 3A-7

Theory of Operation
Air Induction System

The air volume entering the engine at idle is controlled by the idle air control (IAC) valve, which is modulated by the engine
control module (ECM). The IAC valve duty cycle is dependent on the throttle position sensor (TPS) value, manifold absolute
pressure (MAP) sensor value, air temperature values, and engine RPM.
The position of the IAC valve is controlled by the ECM. At idle speed, the ECM compares the actual engine RPM with the
desired engine RPM. If the actual engine RPM is below the desired engine RPM, the ECM supplies voltage to the IAC valve to
increase its duty cycle, allowing more air to enter the engine to raise the engine RPM to the desired speed. The IAC valve is
operated with an electric solenoid.
At speeds above idle, air enters the air induction system through the throttle body, which is a mechanical valve that controls the
amount of air entering the intake manifold runners. The TPS is mounted to the throttle body. The TPS sends an electrical signal
to the ECM to signal how far the throttle body has been opened.
The intake manifold runners allow the air to flow smoothly to the combustion chamber. Each runner has a single fuel injector
controlled by the ECM. The fuel injector has an orifice plate which contains small holes. The orifice plate design allows for a
better atomization of the fuel with the air. The injectors spray the fuel directly at the intake valves.
Fuel Injection System

The fuel injection system is a synchronous (batch timed) multiport injection system. The fuel delivery system, in conjunction
with the ignition system, is controlled by the engine control module (ECM). The ECM requires input data from multiple sensors
to maintain optimum fuel injection volume (pulse width) and fuel injection timing. The ECM uses information received from the
various sensors to adjust the idle air control (IAC) valve during engine idle operations, fuel injection timing/volume, and the
amount of engine timing. The ECM indirectly applies 12 volts to the fuel lift pump and highpressure fuel pump through the main
power relay by completing the ground circuit through the ECM.
Fuel pressure changes under different operating conditions. When the engine is under low or high demands, the manifold
absolute pressure changes. The demands of the engine are communicated to the ECM through the manifold absolute pressure
(MAP) sensor value and the throttle position sensor value. Fuel pressure will change in conjunction with the manifold absolute
pressure change. A hose on the intake manifold is connected to the fuel pressure regulator inside the fuel supply module
(FSM). The manifold absolute pressure changes will push or pull the fuel pressure regulator diaphragm, changing the amount
of fuel pressure in the fuel rail. Any excessive fuel pressure is released inside the FSM.
Fuel injection volume is initially charted in the ECM when the system is activated by turning the key to the "ON" position. The
ECM reads the MAP sensor in the intake manifold to determine the ambient barometric (BARO) pressure. The ECM then looks
at the cylinder block coolant temperature and manifold air temperature. The BARO pressure, cylinder block coolant
temperature, and air temperature values are the base for all fueling strategies at startup. Fuel strategy changes constantly
during engine operation.
The fuel is watercooled inside the FSM. While the engine is running, water is pumped up to the powerhead by the water pump
located in the lower unit. Water is pumped up to the engine through a tube that conjoins with the exhaust tube water jacket
located on the port side of the driveshaft housing. A filter on the exhaust tube water jacket allows some of the water to be
diverted to the FSM. The water enters the FSM and passes through two metal tubes and exits outside of the FSM to the
driveshaft housing.
Air Induction and Fuel Injection System

Fuel System Description
The components of the fuel system are:
Main power relay (MPR)
Intake manifold
Engine control module (ECM)
Throttle body
Idle air control (IAC)
Fuel supply module (FSM)
Fuel lift pump
Highpressure fuel pump
Fuel pressure regulator
Fuel cooler
Fuel injector
IMPORTANT: An external electric fuel pump is not allowed by the U.S. Coast Guard.
NOTE: This particular fuel system does not require an external primer bulb although one can be used for priming the fuel
delivery system.
Page 3A-8 90-8M0082471 JULY 2014

Theory of Operation
Main Power Relay (MPR)

The main power relay is located on the starboard side of the engine behind the electrical cover. The main power relay is
controlled by the ECM. After the key is turned on, the main power relay is active for approximately five seconds. The ECM will
not continue to activate the main power relay unless one or more various sensors, or solenoid activation, signal the ECM to
initiate the main power relay. The main power relay supplies 12 volts to the fuel pumps inside the fuel supply module, ignition
coils, fuel injectors, and the alternator.
Intake Manifold
The intake manifold is located on the starboard side of the engine. It is mounted to the cylinder block and cylinder head. The
intake manifold is the mounting component for the throttle body, idle air control (IAC), manifold absolute pressure (MAP)
sensor, and manifold air temperature (MAT) sensor. The intake manifold is manufactured with a material that is extremely
strong, lightweight, and noncorrosive.
The intake manifold is designed with four runners to provide a smooth air flow to each of the combustion chambers. The
individual runners to the combustion chambers significantly increases the distribution of fuel atomization density within the
combustion chamber, producing a more complete combustion of the fuel air mix, which increases the fuel economy and
provides more horsepower.
Engine Control Module (ECM)

The ECM requires 8 volts minimum to operate. If the ECM should fail, the engine will stop running. The inputs to the ECM can
be monitored and tested using the CDS G3 diagnostic interface tool.
The ECM controls the following functions:

Calculates the precise fuel and ignition timing requirements based on engine speed, throttle position, manifold absolute
pressure, manifold air temperature, and cylinder block coolant temperature.
Directly controls the ground circuit to: fuel injectors, ignition coil, main power relay, fuel pumps, diagnostics, Engine
Guardian, and tachometer link (analog tachometer output or link gauge driver).
Indirectly controls the positive circuit to: fuel injectors, ignition coils, and main power relay.
The ECM operates in three modes: stall, start, and run. The ECM also provides for a smooth throttle response between varying
throttle positions and engine loads. A warmup mode is integrated with the run mode and disengaged after the engine
accumulates a given amount of power or engine temperature.
With the ignition key switch "OFF," 12 volts are available from the battery at the fuses and at the alternator.
Stall mode With the ignition key switch in the "ON" position, the ECM is energized and supplies power to the main power
relay for five seconds. It also provides 5 volts power to the sensors. The ECM records barometric pressure from the MAP
sensor, intake air temperature from the MAT sensor, and coolant temperature from the cylinder block coolant temperature
sensor. The ECM will use this information to establish a warmup strategy that will control fuel delivery and engine speed during
warmup and idle.
Start mode When the vessel operator turns the key switch to the "START" position, a 12 volt signal is sent to the ECM to
begin the sequence of turning the engine over by energizing the start relay. The start relay transfers battery voltage to energize
the starter solenoid. While the engine rotates, a pulse will be generated at the crankshaft position sensor which provides the
ECM engine speed information and engages the main power relay. When the key switch is turned to the "START" position
while the engine is running in neutral, the engine will turn off. The ECM completes the ground circuit for the fuel pumps and the
main power relay.
Run mode At approximately 500 RPM, the ECM will transition to the run mode.
The warmup strategy will continue to adjust engine speed with the fuel injector pulse width and engine spark advance until
the engine accumulates a given amount of power.
The MAT sensor, TPS sensor, and MAP sensor are monitored to determine the proper spark timing and fuel needs
necessary to develop the amount of power asked for by the operator.
Throttle Body
The throttle body is located on the intake manifold. The throttle body is mechanically operated with a throttle linkage connected
to a cantilever throttle lever on the starboard side of the engine behind the intake manifold. The cantilever throttle lever position
is controlled at the helm through the remote control assembly or the tiller handle.
90-8M0082471 JULY 2014 Page 3A-9

Theory of Operation
The idle air control (IAC) valve, in conjunction with the throttle body, controls the volume of air entering the intake manifold at
idle. A throttle position sensor (TPS) is mounted on the throttle body and is directly linked to the throttle body valve shaft. As the
demand for engine power is needed, the throttle body valve opening is increased to allow more air to enter the intake manifold.
The position of the throttle valve is sent to the ECM through the TPS. The position of the throttle valve, along with the manifold
absolute pressure (MAP) sensor, the manifold air temperature (MAT) sensor, and the cylinder block coolant temperature
sensor, assist the ECM to determine the optimum fuel injection timing, duration, and the ignition timing.
a a- Throttle body
b- Throttle position sensor (TPS)
c- Manifold air temperature (MAT) sensor
e b d- Idle air control (IAC) valve
e- Throttle linkage
54826
Idle Air Control (IAC) Valve

The IAC valve is located in the front of the intake manifold above the oil filter. The IAC is a modulated duty cycle electrically
operated springloaded solenoid valve which controls the amount of air that bypasses the closed throttle shutter. Signals from
the ECM regulate the duty cycle of the IAC open time. The duty cycle ranges from 0% to 100% open. The IAC controls four
engine operation functions:
Provides additional intake air (bypass) for engine startup
Allows the increased idle RPM during engine warmup
Controls idle speed according to varying engine loads and running conditions
Functions as an electronic dashpot by providing additional bypass during rapid deceleration, preventing the engine from
stalling
54829
Fuel Supply Module (FSM)

The FSM contains the fuel lift pump, highpressure fuel pump, fuel pressure regulator, and the fuel cooler. The FSM is mounted
below the adapter plate at the rear of the engine. There is no needle and seat or float controlling the amount of fuel entering the
FSM. The filling of the FSM is provided by the positive displacement fuel lift pump. Modulation of the fuel lift pump is not
required.
The FSM is a volume displacement module. The volume of entrained air in the FSM, highpressure fuel line and the fuel rail,
must be purged to allow the fuel to reach the top fuel injector on the fuel rail. When the FSM is properly purged, it remains
almost completely filled during engine operation. The fuel pumps are on parallel electrical circuits inside the FSM for power and
ground. Power from the main power relay activates the fuel lift pump and the highpressure fuel pump. Fuel pressure is
controlled by the fuel pressure regulator located inside the FSM.
Page 3A-10 90-8M0082471 JULY 2014

Theory of Operation
Cooling of the fuel occurs with a bilevel heat transfer. Inside the FSM are four metal tubes: two that are large diameter and two
that are smaller diameter. The smaller diameter tubes are inside the large diameter tubes. The large diameter tubes pass water
through them. The large diameter metal tubes cool the reservoir fuel in addition to cooling the fuel that passes through the
smaller diameter tubes from the highpressure pump and fuel pressure regulator.
c
b c a- Fuel pressure regulator manifold reference port
a b- Highpressure fuel out port
c- Fuel cooler water in port
f
d- Fuel in port (from vessel)
c
e- Fuel cooler water out port
f- Fuel cooler fuel tube
d
e
47841
e
Fuel Lift Pump

The fuel lift pump located inside the FSM, pulls fuel from the fuel tank. The fuel lift pump is activated with 12 volts through the
main power relay when the key is turned to the "ON" position for approximately five seconds when there is no engine rotation.
The grounding of the fuel lift pump is completed in the ECM. The ECM does not have the logic to detect the fuel lift pump
operation. In the event of a fuel lift pump failure, no fault will be generated and the engine will not run.
The fuel lift pump has fuel passing through it constantly when the FSM is full of fuel. A fuel recirculating check valve inside the
FSM is conjoined with the fuel lift port passage. When fuel cannot be pulled into the FSM from the fuel tank (FSM is full), the
check valve opens and allows the cooled fuel inside the FSM to pass through the fuel lift pump, preventing the pump from
overheating. The FSM is a volume displacement module which replaces the fuel inside the FSM automatically without the
installation of a float switch or needle and seat.
47837
90-8M0082471 JULY 2014 Page 3A-11

Theory of Operation
HighPressure Fuel Pump

When the ignition key is turned "ON," the highpressure fuel pump is active for approximately five seconds. After the first five
seconds, the highpressure fuel pump will not run until the ECM recognizes engine RPM. The ECM does not have the logic to
detect the highpressure fuel pump operation. In the event of a highpressure fuel pump failure, no fault will be generated and
the engine will not run. The highpressure fuel pump sends the fuel through a 20 micron fuel filter and into the bottom of the fuel
rail. There is an internal regulation of the highpressure pump of 689.5 kPa (100 psi). The fuel rail pressure is controlled by a
fuel pressure regulator. The fuel pressure dumped by the fuel pressure regulator passes through a fuel cooler. Passing the
excessive fuel through the fuel cooler prevents the highpressure fuel pump from overheating.
47839
Fuel Pressure Regulator

The fuel pressure regulator, located inside the fuel supply module, controls the amount of fuel pressure required for the engine
to run efficiently. The fuel pressure regulator changes the pressurization of the fuel depending on the demands of the engine.
Air pressure in the intake manifold changes to a higher or lower pressure during RPM changes. These manifold air pressure
changes are linked to the fuel pressure regulator. The changes which take place at the fuel pressure regulator are managed by
a hose that is connected to the intake manifold. The air pressure change that is positive or negative on the fuel pressure
regulator diaphragm, increases or decreases the amount of fuel that is returned back into the FSM. The fuel pressure dumped
by the fuel pressure regulator passes through a fuel cooler. Passing the excessive fuel through the fuel cooler prevents the
highpressure and lowpressure fuel pumps from overheating.
47840
Page 3A-12 90-8M0082471 JULY 2014

Theory of Operation
Inline Fuel Filter

The inline fuel filter is located inside the inlet end of the fuel rail, near the bottom of the intake manifold on the starboard side of
the powerhead. This inline fuel filter consists of a oneway, reusable filter element. The filter can be removed from the fuel rail
and cleaned as part of normal maintenance, or in the event of fuel contamination. The filter element can be cleaned by
backflushing the element with a locally available fuel system cleaner. Replacement is not required unless the inline fuel filter is
damaged, punctured, or otherwise unsuitable for use.
55858
In-line fuel filter
Fuel Injector
The fuel injector is an electrically operated springloaded solenoid which delivers a metered amount of fuel into the intake
manifold runner, just ahead of the intake valve. The injectors are electrically charged when the key switch is turned to the "ON"
position. The ECM controls the injection by completing the ground circuit, lifting the solenoid, which allows highpressure fuel to
flow. The ECM then opens the ground circuit, allowing the spring to close the injector and stop the fuel flow. The fuel injector is
not serviceable. The fuel injector has an orifice plate which contains small holes. The orifice plate design allows for a better
atomization of the fuel with the air. The injectors spray the fuel directly at the intake valves. An injector filter is located on the
fuel inlet side of the injector. The filter is not replaceable but can be cleaned of debris.
a - Orings
b - Filter
a 48187
Guardian Protection System

The Guardian Protection System monitors critical engine functions and will reduce engine power accordingly in an attempt to
keep the engine running within safe operating parameters.
IMPORTANT: The Guardian Protection System cannot guarantee that powerhead damage will not occur when adverse
operating conditions are encountered. The Guardian Protection System is designed to 1) warn the boat operator that the
engine is operating under adverse conditions and 2) reduce power by limiting maximum RPM in an attempt to avoid or reduce
the possibility of engine damage. The boat operator is ultimately responsible for proper engine operation.
90-8M0082471 JULY 2014 Page 3A-13

Theory of Operation
Fuel Flow Diagram
j
g
f i h f
d
e l
k
b
56251
Page 3A-14 90-8M0082471 JULY 2014

Theory of Operation
a- Fuel inlet from vessel h- Siphon tube
b- Lowpressure fuel filter (20 microns) i- Highpressure fuel pump
c- Fuel supply module j- Highpressure fuel
d- Fuel lift pump k- Highpressure fuel hose
e- Recirculation check valve l- Inline fuel filter (located inside the fuel rail)
f- Fuel cooler m- Fuel rail and injectors
g- Fuel pressure regulator
90-8M0082471 JULY 2014 Page 3A-15

Theory of Operation
Notes:
Page 3A-16 90-8M0082471 JULY 2014

Troubleshooting and Diagnostics
Fuel Systems
Section 3B - Troubleshooting and Diagnostics
Table of Contents
3
Troubleshooting Without a CDS G3 Diagnostic Interface Idle Air Control (IAC)..........................................................3B-5
Tool................................................................................ 3B-3 Idle Air Control (IAC) Testing......................................3B-5
Fuel Supply Module Priming Procedure............................ 3B-3 Fuel Pumps........................................................................3B-6
Priming the FSM with a Fuel Pressure Gauge........... 3B-3
Priming ProcedureWithout Purging the FSM ......... 3B-4
Fuel Supply Module Fuel Pumps................................3B-6
Fuel Lift Pump ............................................................3B-7
B
AntiSiphon Valves.............................................................3B-4 HighPressure Fuel Pump.......................................... 3B-8
Referencing Fuel Pressure Readings................................ 3B-4 Fuel Injectors..................................................................... 3B-8
Fuel Pressure Calculations, Engine Running.................... 3B-4 Fuel Injector and Harness Resistance Test................3B-9
Wire Color Code Abbreviations..........................................3B-5 Fuel Injector and Harness Voltage Test..................... 3B-9
90-8M0082471 JULY 2014 Page 3B-1


25 Liquid Neoprene Grounds and ring terminals 92- 25711 3
Special Tools
Fuel Pressure Gauge Kit 91881833A03
Tests the fuel pump pressure; can be used to relieve fuel pressure.
2807
instruction sheet.
41993

V Hz
H z TEMP
mA
A
mV IG
OFF IP
TEMP
A mA COM V Hz
4516
Dual Fuel/Air Pressure Gauge Kit 91881834A 1
Tests fuel and air pressure; the dual gauges allow the viewing of both pressures
simultaneously.
5822
Digital Pressure Meter 91892651A01
Connects to the fuel system/manifold and can be used in conjunction with

Computer Diagnostic System (CDS).
5786
Page 3B-2 90-8M0082471 JULY 2014

Troubleshooting Without a CDS G3 Diagnostic Interface Tool

Troubleshooting without the CDS G3 diagnostic interface tool is limited to checking resistance on some of the sensors and
actuators.
Typical failures usually do not involve the engine control module (ECM) and may not be related to the engine systems. Fuel
systems problems can occur on the boat side of the fuel system (such as antisiphon valves, the boat fuel tank, water in fuel, or
fuel phase separation). Most likely engine system faults are usually the electrical connectors or splice points, and mechanical
wear.
The engine may not run or may not run above idle with the wrong spark plugs installed.
Swap ignition coils to see if the problem follows the coil or stays with the particular cylinder.
NOTE: Some ECMs are capable of performing a cylinder misfire test to isolate problem cylinders. Once a suspect cylinder
is located, an output load test on the ignition coil or fuel injector can be performed using the CDS G3 diagnostic interface
tool.
Any sensor or connection can be disconnected and reconnected while the engine is operating without damaging the ECM.
Disconnecting the crankshaft position sensor will stop the engine.
IMPORTANT: Any sensor that is disconnected while the engine is running will be recorded as a fault in the ECM Fault
History. Use the CDS G3 diagnostic interface tool to view and clear the fault history when troubleshooting/repair is
completed.
If all cylinders exhibit similar symptoms, the problem is with a sensor or harness input to the ECM.
If the problem is speed related or intermittent, it is probably connector or contact related. Inspect connectors for corrosion,
loose wires, or loose pins. Verify all the connectors are properly latched together and the engine harness is restrained with
cable ties or retainers as shown in the appropriate section of the service manual. If dielectric compound was used to
protect the wire connections, the dielectric compound must be removed.
Inspect the harness for obvious damage: pinched wires, chafing.
Secure grounds and all connections involving ring terminals. Apply Liquid Neoprene to all grounds and ring terminals.

25 Liquid Neoprene Grounds and ring terminals 92- 25711 3
Check fuel pump connections and fuel pump pressure.
Fuel Supply Module Priming Procedure

The fuel supply module (FSM) is not vented to the ambient air. The air trapped in the FSM, fuel lines, and fuel rail, will be
slightly compressed during the initial ignition keyon with a dry or drained fuel system. Additional keyon events under these
conditions, will not compress the air further to finish the priming of the FSM. Excessive number of keyon events may eventually
damage the fuel pumps. The volume of air trapped in the FSM must be purged to prime the fuel system. This can be achieved
by connecting a tool to the fuel rail Schrader valve fitting to quickly purge the system into an approved container, or by cranking
the engine.
Priming the FSM with a Fuel Pressure Gauge

The use of a purge tool for priming the FSM is the preferred method, but is not always practical. The objective is to purge the
air entrained in the fuel system through a purge tool connected to the fuel rail Schrader valve test port. During the keyon,
opening the Schrader valve will allow the air to be purged from the FSM and fuel rail. This method should be used on vessels
where the fuel inlet system to the outboard is restrictive, has an antisiphon valve, or holds a relatively large volume of fuel
because of a long fuel supply line or water separating fuel filter. If a primer bulb is installed, it can be used during the priming
event to shorten the amount of time required to start the engine.
1. Verify the engine is in a level vertical position.
2. Verify the vessel fuel supply line is connected to the outboard fuel system inlet fitting.
3. Connect a fuel pressure gauge to the fuel rail Schrader valve.

4. Secure the fuel pressure gauge purge hose into an appropriate fuel container to collect excess fuel.
5. Open the fuel pressure gauge purge valve and turn the ignition key on. The fuel pumps will run for approximately five
seconds.
6. Turn the ignition key off and then back on. The fuel pumps will run for approximately five seconds. Continue this ignition
key cycle until the purged fuel is relatively clear of air bubbles.
NOTE: If the outboard fuel system does not prime within 15 keyon events, check for leaks in the fuel supply line to the
outboard. Repair as needed. If no leak is found, the fuel supply system to the outboard may be too restrictive. Correct the
condition and try again.
90-8M0082471 JULY 2014 Page 3B-3

7. Remove the fuel pressure gauge.

8. Turn the ignition key on. When the fuel pumps stop running, start the engine. The engine may not start on the first attempt.
The engine will run rough at idle for up to two minutes while the residual air is purged from the fuel system.
Priming ProcedureWithout Purging the FSM

The use of a purge tool for priming the FSM is the preferred method, but is not always practical. When the vessel fuel system is
void of fuel volume, it can be primed without the use of a purge tool. The objective is to purge the air entrained in the fuel
system through the fuel injectors during engine cranking to allow fuel to enter the fuel module. This method can be used on
vessels where the fuel inlet system to the outboard is less restrictive and holds a relatively small volume of fuel; a short fuel
supply line, no water separating fuel filter, or water separating fuel filter is already primed. If a primer bulb is installed, it can be
used during the priming event to shorten the amount of time required to start the engine.
1. Verify that the engine is in a vertical position.
2. Verify that the vessel fuel supply line is connected to the outboard fuel system inlet fitting.
3. Turn the ignition key on. The fuel pumps will run for approximately five seconds.
4. Turn the ignition key to the "START" position and release the key. The ECM controls the activation of the starter. The
starter may continue cranking for up to eight seconds.
NOTE: When priming a drained fuel system, residual fuel may cause the engine to flare and stall which shortens the
engine cranking event.
5. Continue with the ignition key on and start sequence until the engine continues to run.
IMPORTANT: Allow the starter motor to cool for 20 to 30 seconds between full eight second crank events. Limit the
number of events to a maximum of 10 full eight second cranking events.
6. Once the engine starts, it may run rough at idle for up to two minutes while the residual air is purged from the fuel system.
7. If the fuel system will not prime within 10 full eight second cranking events, use the previous procedure Priming the FSM
with a Fuel Pressure Gauge to prime the fuel system.
AntiSiphon Valves
While antisiphon valves may be helpful from a safety standpoint, they clog with debris, they may be too small, or they may
have too heavy a spring. The pressure drop across these valves can, and often does, create operational problems and/or
powerhead damage by restricting fuel to the fuel lift pump and, subsequently, the highpressure fuel pump. Some symptoms of
restricted (lean) fuel flow, which could be caused by use of an antisiphon valve, are:
Severe fuel rail pressure fluctuation
Loss of fuel pump pressure
High speed surging
Outboard cuts out or hesitates upon acceleration
Outboard runs rough
Outboard quits and cannot be restarted
Outboard will not start
Vapor lock
A simple method of checking if an antisiphon valve (or bad fuel) is a problem source is to operate the outboard with fresh fuel
in a portable fuel tank. This will isolate problems caused by overly restrictive antisiphon devices or bad fuel.
If, after using a separate fuel supply, it is found that the antisiphon valve is the cause of the problem, there are two solutions to
the problem; either 1) replace the antisiphon valve with one that has a lighter spring tension, or 2) replace it with a
solenoidoperated fuel shut off valve.
Referencing Fuel Pressure Readings

The fuel rail pressure is regulated by a fuel pressure regulator located inside the fuel supply module, and is subject to
atmospheric differential pressure variance. The fuel pressure regulator pressure reference reading while the engine is static
(not running) is approximately 340370 kPa (49.353.7 psi). The fuel pressure regulator is factory set to 350 32 kPa
(50.76 4.64 psi). A reference hose is connected between the intake manifold and the fuel pressure regulator. The intake
manifold vacuum affects the amount of fuel pressure needed to unseat the fuel pressure regulator. The intake manifold vacuum
pulls on the fuel pressure regulator diaphragm, allowing the fuel pressure regulator to open at a lower pressure than the factory
set point. The amount of vacuum inside the intake manifold is directly related to the engine RPM and the position of the throttle.
Fuel Pressure Calculations, Engine Running

When calculating the fuel pressure at different points of engine RPM, a simple formula can be used to determine what the fuel
pressure should approximately be: (MAP Barro) + regulator set point.
The following examples are with an ambient barometric pressure of 101 kPa (14.65 psi).
Page 3B-4 90-8M0082471 JULY 2014

If the intake manifold absolute pressure is below the barometric pressure (vacuum), and the CDS G3 diagnostic interface tool
displays 32 kPa (4.64 psi), the formula appears as:
kPa: 32 101 = 69 + 350 = 281. The calculated fuel pressure reading is 281 kPa.
PSI: 4.64 14.65 = 10.01 + 50.76 = 40.66. The calculated fuel pressure reading is 40.75 psi.

BLK Black BLU Blue
BRN Brown GRY Gray
RED Red TAN Tan
Idle Air Control (IAC)

The IAC is located on the intake manifold. The IAC is a modulated duty cycle electrically operated springloaded solenoid valve
which controls the amount of air that bypasses the closed throttle shutter. Signals from the ECM regulate the duty cycle of the
IAC open time. The duty cycle ranges from 0% to 100% open.
One side of the IAC valve is exposed to the ambient air pressures under the cowl. The other side of the IAC valve is exposed to
the intake manifold vacuum pressures. When the IAC is activated, the armature lifts, opening the control orifice which is
normally springloaded closed. The IAC valve has a rubber stopper on the end of it.
55021
Idle Air Control (IAC) Testing

The CDS G3 diagnostic interface tool will display the duty cycle of the IAC by providing a numerical percentage of the time the
IAC solenoid is as a fraction of the total time under consideration.
1. Disconnect the engine harness from the IAC.

2. Disconnect the engine harness ECM connector at the ECM.
3. Use the DMT 2004 digital multimeter to perform an ohm check on the engine harness between the IAC connection and the
ECM connection.

4. Set the meter to read ohms, auto scale.
5. Connect the red meter lead to the ECM connector, pin 3.
6. Connect the black meter lead to the IAC harness connector, pin 1.
7. If the results of the test is not within specifications, check for corrosion or an open connection. Repair as needed.
8. Connect the red meter lead to the ECM connector, pin 57 or 58. These two wires are spliced in the harness.
9. Connect the black meter lead to the IAC harness connector, pin 2.
90-8M0082471 JULY 2014 Page 3B-5

10. If the results of the test is not within specifications, check for corrosion or an open connection. Repair as needed.
c
1 18 34 51 C12
WHT/LT BLU
RED/BLU
67 a A B
68
WHT/LT BLU
69 57 RED/BLU
S104
58 RED/BLU
70
17 33 50 66 54952
a- ECM connector
b- IAC
c- Main power relay
d- 20amp fuse
Meter Test Leads

Red Black
ECM connector, pin 3 IAC harness connector, pin 1 (white/lt blue) Auto Less than 1
ECM connector, pin 57 or 58 IAC harness connector, pin 2 (red/blue) Auto Less than 1
11. Connect the engine harness to the IAC.
12. Connect the engine harness ECM connector to the ECM.
Fuel Pumps
Fuel Supply Module Fuel Pumps
The fuel lift pump and highpressure pump is activated with 12 volts through the main power relay when the key is turned to the
"ON" position. The fuel pump circuit, in conjunction with the idle air control, fuel injectors, and start relay, are protected with a
20amp fuse. The grounding of the fuel pump circuit is completed inside the engine control module. Modulation of the fuel lift
pump is not required because the fuel delivery system is one way and deadheads at the top of the fuel rail.
Page 3B-6 90-8M0082471 JULY 2014

The fuel lift pump and highpressure pump are on a parallel circuit inside the fuel supply module and cannot be electrically
tested separately when installed as part of the fuel supply module assembly. The fuel pumps will run for approximately five
seconds when the ignition key is turned on and no engine rotation is sensed by the engine control module. While the fuel
pumps are active, a vacuum test on the fuel lift pump, and a pressure reading on the highpressure pump, should be performed
when troubleshooting the fuel pumps. The fuel pumps circuit can be activated by the CDS G3 diagnostic interface tool.
d
b c
1 18 34 51
RED/WHT
RED
RED/YEL
RED/ORN
RED
RED/WHT
RED/BLU
RED/PPL
67
a
YEL/PPL
RED/WHT
RED/PPL
RED
68
RED/BLU
RED/BLK
S103
69
S120
70
17 33 50 66
55073
a- ECM connector
b- Highpressure fuel pump
c- Fuel lift pump
d- 20amp fuse
e- Main power relay
Fuel Lift Pump

The fuel lift pump and highpressure pump are on a parallel circuit inside the fuel supply module. The fuel lift pump cannot be
electrically tested separately from the highpressure pump when installed as part of the fuel supply module assembly. The fuel
lift pump can be tested for operation electrically with the CDS G3 diagnostic interface tool.
The fuel lift pump is activated with 12 volts through the main power relay when the key is turned to the "ON" position. The fuel
pump circuit, in conjunction with the idle air control, fuel injectors, and start relay, are protected with a 20amp fuse. The
grounding of the fuel pump circuit is completed inside the engine control module. Modulation of the fuel lift pump is not required
because the fuel delivery system is one way and deadheads at the top of the fuel rail.
There is no logic in the engine control module to know if the fuel lift pump is functioning or not. No fault will be set if the fuel lift
pump fails.
Testing Fuel Lift Pump Vacuum

1. Separate the engine fuel line and the boat fuel line.
2. Install a Tfitting on the boat fuel line.
3. Install a clear fuel line on the opposite side of the Tfitting. Connect the clear fuel line to the engine fuel line.
4. Install a fuel vacuum gauge (obtain locally) on the Tfitting.
5. Clamp all fuel line connections securely to prevent vacuum leaks.
90-8M0082471 JULY 2014 Page 3B-7

6. Start the engine and observe the clear fuel line for air bubbles. If the engine does not start, use the CDS G3 diagnostic
interface tool.

7. The vacuum gauge reading should be within the listed specification when the pump is active.
a- Engine fuel line

b- Clear fuel line
c- Tfitting
d- Boat fuel line
a d
b c
4439
Fuel Lift Pump Vacuum

Maximum 10.16 kPa (3.00 in. Hg)

The highpressure fuel pump and fuel lift pump are on a parallel circuit inside the fuel supply module. The highpressure fuel
pump cannot be electrically tested separately from the fuel lift pump when installed as part of the fuel supply module assembly.
The highpressure fuel pump can be tested for operation electrically with the CDS G3 diagnostic interface tool.
The highpressure fuel pump is activated with 12 volts through the main power relay when the key is turned to the "ON"
position. The fuel pump circuit, in conjunction with the idle air control, fuel injectors, and start relay, are protected with a 20amp
fuse. The grounding of the fuel pump circuit is completed inside the engine control module. The fuel delivery system is one way
and deadheads at the top of the fuel rail.
There is no logic in the engine control module to know if the highpressure fuel pump is functioning or not. No fault will be set if
the highpressure fuel pump fails.
1. Connect a fuel pressure gauge to the fuel rail Schrader valve.

Dual Fuel/Air Pressure Gauge Kit 91881834A 1
Digital Pressure Meter 91892651A01
2. Perform the fuel pump load test with the CDS.
3. The fuel pressure gauge should be within specifications.

Fuel pressure, engine not running 340370 kPa (49.353.7 psi)
Fuel pressure, engine running Pressure dependent on manifold vacuum pressure
4. If there is little or no pressure reading on the gauge, ensure the fuel supply module has enough fuel to supply the
highpressure fuel pump. It may be necessary to perform a fuel supply module priming to verify the system is purged of
entrained air.
Fuel Injectors
The fuel injector is an electrically operated springloaded solenoid, which delivers a metered amount of fuel into the intake
manifold runner, just ahead of the intake valve. The injectors are electrically charged through the main power relay when the
ignition key is turned to the "ON" position. The engine control module controls the injection by completing the ground circuit,
lifting the solenoid, which allows highpressure fuel to flow. The engine control module then opens the ground circuit allowing
the spring to close the injector and stop the fuel flow. The fuel injector is not serviceable. An injector filter is located on the fuel
inlet side of the injector. The filter is not replaceable, but can be cleaned of debris. The fuel injectors can be tested with an
ohmmeter or the CDS G3 diagnostic interface tool.
Page 3B-8 90-8M0082471 JULY 2014

Fuel Injector and Harness Resistance Test

c d e
b f g
RED/BLU
RED/BLU
RED/BLU
RED/PNK
ORN/PNK
YEL/PNK
BRN/PNK
RED/BLU
RED/BLU
1 18 34 51
67 a S120
68
57
69
58
70 55076
17 33 50 66
a- ECM connector
b- Fuel injector #1
c- Fuel injector #2
d- Fuel injector #3
e- Fuel injector #4
f- Main power relay
g- 20amp fuse
1. Verify the fuse is good.

2. Disconnect the engine harness ECM connector at the ECM.
3. Use the DMT 2004 digital multimeter to perform an ohm check on each of the injector circuits (injectors connected).
4. If the resistance is out of specification, disconnect the engine harness connector from the fuel injector and test the fuel
injector for the resistance specification.
5. If the injector is in specification, connect the engine harness connector. Shake or move the harness and connector. If the
meter readings change during the tests, inspect for a broken, loose, or corroded wire. Repair the problem wire and test the
circuit.
Meter Test Leads

Red Black
Pin 49 (fuel injector #1) (brown/pink) Auto 12 0.5
Pin 50 (fuel injector #2) (red/pink) Auto 12 0.5
Pin 57 or 58 (red/blue)
Pin 65 (fuel injector #3) (orange/pink) Auto 12 0.5
Pin 48 (fuel injector #4) (yellow/pink) Auto 12 0.5
Fuel Injector and Harness Voltage Test

1. Perform a visual inspection of the pins at the fuel injector and the wires coming to the engine harness connector. Look for
broken, bent, and corroded pins at the fuel injector; and loose, broken, or corroded wires at the engine harness connector.
90-8M0082471 JULY 2014 Page 3B-9

NOTE: Shake or move the harness and connector when performing the following tests. If the meter readings change
during the tests, inspect for a broken, loose, or corroded wire. Repair the problem wire and retest the circuit.
2. Connect the meter between the red/blue pin at the fuel injector connector and a common engine ground. Ensure the meter
is set to read voltage, auto scale.
3. Turn the ignition key switch to the "ON" position.
NOTE: With the ignition key switch in the "ON" position and the engine off, battery voltage is only available to the red/blue
wire for five seconds when no crankshaft position sensor signal is received by the engine control module.
a. If battery voltage is not present, check to ensure the main power relay is functioning.
b. If battery voltage is not present and the main power relay is functioning properly, check to ensure the 20amp fuse is
not blown.
NOTE: The main power relay must be on for battery voltage to be present at the red/blue wire. If battery voltage is not
present, the main power relay may be defective or the 20amp fuse is blown.
c. If battery voltage is not present with the main power relay functioning properly, and the fuel injector fuse is not blown,
there is an open circuit between the main power relay red/blue wire and the splice in the engine harness connector.
NOTE: The 12 volt power supply for the fuel injectors are spliced together at several different locations in the engine
harness. If the red/blue wire at the fuel supply module fuel pump connector and all of the fuel injector red/blue wires
have no battery voltage, an open circuit at the engine wire harness splice point is the most likely failure.
4. Check for continuity between the red/blue wire on each of the fuel injector engine harness connectors and the red/white
wire at the main power relay. This test includes the fuel injector fuse. Ensure the fuel injector fuse is not blown.
Page 3B-10 90-8M0082471 JULY 2014

Service Procedures
Fuel Systems
Section 3C - Service Procedures
Table of Contents
3
Fuel System Specifications................................................3C-2 Fuel Rail Assembly and Installation............................3C-8
Throttle Body..................................................................... 3C-2 Fuel Supply Module (FSM).............................................. 3C-11
Throttle Body Removal............................................... 3C-2 FSM Removal...........................................................3C-11
Throttle Body Installation............................................ 3C-4
Fuel Rail.............................................................................3C-6
FSM Disassembly.....................................................3C-13
FSM Assembly......................................................... 3C-16
C
Fuel Rail Removal and Disassembly..........................3C-6 FSM Installation........................................................3C-23
90-8M0082471 JULY 2014 Page 3C-1

Service Procedures

Automotive unleaded with a minimum pump posted octane rating of 87 (90
Type of fuel
RON)
Approximate fuel pressure at idle 280310 kPa (40.645.0 psi)
Approximate fuel pressure engine not running 340370 kPa (49.353.7 psi)
Fuel filtration
Fuel inlet 20 microns
High pressure 20 microns

Threads of the screw that secures the MAP sensor/wire harness
retainer
O-rings
Seal grommet
95 2-4-C with PTFE Both seal grommets 92-802859A 1
Fuel pressure regulator O-rings
O-rings and seal grommets
Special Tools
Clamp Tool 91803146T
Used to clamp highpressure (Oetiker) hose clamps. Part of Clamp Tool Kit
39648 (91803146A4).
Throttle Body
Throttle Body Removal
2. Remove the vent hose assembly from the throttle body.
3. Disconnect the throttle linkage from the throttle body lever.
4. Disconnect the engine harness connector from the throttle position sensor.
a - Throttle linkage
c
b - Vent hose assembly
b c - Throttle position sensor connector
55031
5. Disconnect the engine harness connector from the manifold absolute pressure (MAP) sensor.
Page 3C-2 90-8M0082471 JULY 2014

Service Procedures
6. Remove the screw securing the MAP sensor/wire harness retainer to the throttle body. Move the retainer so it is clear of
the MAP sensor.
a - MAP sensor connector

b
b - Screw securing the MAP sensor/wire harness retainer
55032
7. Remove the MAP sensor by pulling it upwards while rotating the sensor back and forth.
55034
8. Remove four screws securing the throttle body to the intake manifold. Remove the throttle body from the manifold.
55035
90-8M0082471 JULY 2014 Page 3C-3

Service Procedures
9. Remove the two screws securing the throttle position sensor (TPS) to the throttle body. Remove the TPS.
a - TPS
b - Screws (2)
b 55036
Throttle Body Installation

1. Install the throttle position sensor onto the throttle body throttle shaft.
2. Rotate the throttle position sensor clockwise to align the screw holes.
55039
3. Install the screws and tighten them to the specified torque.
a - TPS
b - Screws (2)
b 55036

Throttle position sensor screws (2) 4 35.4
4. Replace the throttle body seal on the intake manifold.
5. Install the throttle body and secure with four M6 x 20 screws. Tighten the screws to the specified torque.
Page 3C-4 90-8M0082471 JULY 2014

Service Procedures
IMPORTANT: Do not overtighten the throttle body screws or damage to the intake manifold will result.
55035

Screws (M6 x 20) (4) 7 61.9
6. Install the MAP sensor onto the throttle body.
55034
7. Connect the engine harness connector to the MAP sensor.

8. Install the MAP sensor/wire harness retainer onto the throttle body. Apply Loctite 242 Threadlocker to the threads of the
screw that secures the MAP sensor/wire harness retainer. Install the screw handtight.
a - MAP sensor connector

b
b - Screw securing the MAP sensor/wire harness retainer
55032

Threads of the screw that secures the MAP sensor/wire
harness retainer
90-8M0082471 JULY 2014 Page 3C-5

Service Procedures
9. Connect the engine harness connector to the throttle position sensor.
10. Connect the throttle linkage to the throttle body lever.
11. Install the vent hose assembly onto the throttle body.
a - Throttle linkage
c
b - Vent hose assembly
b c - Throttle position sensor connector
55031
Fuel Rail
Fuel Rail Removal and Disassembly
Fuel Rail Removal
! WARNING
! CAUTION
Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the
engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and
skin from pressurized fuel and vapors.
1. Disconnect the battery cables.

2. Connect a fuel pressure gauge to the fuel rail test port and release the fuel pressure into an appropriate container.
3. Cut the cable tie securing the fuel pump connector to the fuel rail.
4. Disconnect the fuel pump connector from the engine harness.
a - Fuel rail
b - Cable tie
c - Fuel pump connector
a
b
c
54897
5. Remove the metal hose clamp and remove the highpressure fuel hose from the fuel rail. Capture the fuel that will drain
from the fuel rail and highpressure fuel hose into an appropriate container.
Page 3C-6 90-8M0082471 JULY 2014

Service Procedures
NOTE: Use care while removing the highpressure fuel hose from the fuel rail. The inline fuel filter (located in the inlet side
of the fuel rail) may become dislodged while removing the highpressure fuel hose. If this occurs, press the inline fuel filter
into the fuel rail until you hear a click.
a - Fuel rail
b - Metal hose clamp
c - Highpressure fuel hose
a
b
c
54898
6. Disconnect the engine harness connectors from the fuel injectors.

7. Remove the screws securing the fuel rail to the intake manifold.
a - Engine harness connectors

b - Screws securing the fuel rail
c - Fuel rail test port
a b
c
a
b
a
b
a
b
55029
8. Pull the fuel rail assembly off of the intake manifold.
Fuel Rail Disassembly

1. Push the fuel injector retainer off of the fuel injector and fuel rail.
2. Pull the fuel injector off the fuel rail.
a - Fuel injector retainer
48186
3. Remove the inline fuel filter from the fuel rail.
90-8M0082471 JULY 2014 Page 3C-7

Service Procedures
IMPORTANT: Remove the fuel filter by hand. Do not use tools or damage to the filter may result.
a - Fuel injector
b - Fuel rail
c - Inline fuel filter
a b
55859
4. Inspect the inline fuel filter. Clean or replace the filter as necessary.
Fuel Rail Assembly and Installation

Fuel Rail Assembly
IMPORTANT: The fuel injector filter is not serviceable, but can be cleaned with a mild solvent and compressed air.
1. Before installing the fuel injectors, flush the fuel rail with a mild solvent. Use compressed air to remove any possible debris
from inside the fuel rail.
2. Replace the fuel injector Orings.
a - Orings
b - Filter
a 48187
3. Push the filter end of the fuel injector into the fuel rail. Verify the fuel injector retainer groove is above the fuel rail injector
port.
48188
4. Align the fuel injector retainer with the fuel rail and the fuel injector retainer groove.
Page 3C-8 90-8M0082471 JULY 2014

Service Procedures
5. Push the fuel injector retainer onto the fuel rail and fuel injector.
a - Fuel injector retainer
48191
6. Install the inline fuel filter into the fuel rail by hand.
IMPORTANT: Do not use tools to install the inline fuel filter or damage may result.
a - Fuel injector
b - Fuel rail
a b
55859
Fuel Rail Installation

1. Push the fuel rail assembly onto the intake manifold and secure with four M6 x 20 screws. Tighten the screws to the
specified torque.
IMPORTANT: Do not overtighten the fuel rail mounting screws or damage to the intake manifold will result.

Screws (M6 x 20) (4) 7 61.9
90-8M0082471 JULY 2014 Page 3C-9

Service Procedures
2. Connect the engine harness connectors onto the fuel injectors. Ensure that the fuel rail test port is capped.
a - Engine harness connectors

b - M6 x 20 screws (4)
c - Fuel rail test port
a b
c
a
b
a
b
a
b
55029
3. Install a 16.2 mm metal hose clamp onto the highpressure fuel hose.
4. Ensure that the inline fuel filter is installed into the end of the fuel rail.
IMPORTANT: Install the inline fuel filter by hand. Do not use tools to install the filter or damage may result.
a - Fuel injector
b - Fuel rail
a b
55859
5. Install the highpressure fuel hose onto the fuel rail.

6. Secure the hose with the metal hose clamp using the hose clamp tool.
a - Fuel rail
b - 16.2 mm metal hose clamp
a
b
c
54898

7. Connect the fuel pump connector to the engine harness connector.
Page 3C-10 90-8M0082471 JULY 2014

Service Procedures
8. Secure the fuel pump connector to the fuel rail with a cable tie.
a - Fuel rail
b - Fuel pump connector
c - Cable tie
a
b
c
54897
9. Connect the battery cables.
Fuel Supply Module (FSM)

FSM Removal
1. Release the fuel pressure on the fuel rail. Refer to Fuel Rail Removal.
! CAUTION
IMPORTANT: The FSM does not have a drain port incorporated into the upper or lower housing. If the FSM requires
disassembly, the extraction of fuel in the FSM can be accomplished with the following method.
Disconnect the fuel supply hose on the FSM. Attach a fuel pressure gauge to the fuel rail test port. Drain the fuel with the
pressure gauge into an appropriate container by turning the key switch on several times while holding the purge valve
open, or use the CDS G3 diagnostic interface tool to energize the fuel pumps.
2. Disconnect all batteries from the engine.
3. Remove the remote control harness, fuel line, throttle, and shift cables.
4. Remove the lower cowls. Refer to Section 5A Lower Cowl.
5. Remove the idle exhaust muffler from the adapter plate by lifting it up and away from the adapter plate.
a - Idle exhaust muffler

b - Adapter plate
b
54893
6. Cut the cable tie securing the fuel pump harness connector to the fuel rail.
90-8M0082471 JULY 2014 Page 3C-11

Service Procedures
7. Disconnect the fuel pump harness connector from the engine harness.
a - Fuel rail
b - Fuel pump harness connector
c - Cable tie
a
b
c
54897
8. Remove the 16.2 mm metal hose clamp securing the highpressure fuel hose to the fuel rail. Remove the highpressure
fuel hose from the fuel rail.
NOTE: The inline fuel filter may become dislodged from the fuel rail when removing the highpressure fuel hose. Press the
inline fuel filter into the rail by hand if it becomes dislodged.
a - Fuel rail
a
b
c
54898
9. Push the lock in and remove the manifold pressure reference line from the FSM.
a a - Manifold pressure reference line
54899
10. Cut the cable tie securing the FSM cooling water supply hose and remove the hose.
c a- Manifold pressure reference line (removed)

b- FSM
c- Cooling water supply hose
d- Cable tie
b d
a
55052
11. Cut the cable tie securing the water hose and remove the hose.
12. Push the lock in and remove the fuel supply hose from the FSM.
NOTE: Fuel will drain from this hose when it is disconnected. Use an appropriate container to capture the fuel.
Page 3C-12 90-8M0082471 JULY 2014

Service Procedures
13. Remove the screw securing the FSM to the FSM mounting bracket.
14. Remove the screw securing the FSM mounting bracket to the driveshaft housing.
15. Pull the FSM out of the driveshaft housing.
a a- Cable tie
b b- Fuel supply hose
c- Water hose
e d- Screw securing the FSM to the FSM mounting bracket
e- Screw securing the FSM mounting bracket to the driveshaft housing
d
55058
FSM Disassembly
NOTE: The FSM cannot be completely drained of fuel prior to disassembly. Use appropriate containers to capture fuel during
the disassembly process. Wipe up fuel spills immediately and dispose of in an appropriate container.
1. Place the FSM in an appropriate container to capture any fuel that will spill.
2. Remove the metal hose clamp securing the highpressure hose to the FSM upper housing and remove the hose.
56209
3. Remove the four screws securing the upper housing to the lower housing.
a - Screws (4)
49136
4. Grasp the lower housing and the upper housing and pull the upper housing slightly to partially separate the upper housing
from the lower housing.
5. Insert two pry tools between the upper and lower housing and carefully separate the housing.
90-8M0082471 JULY 2014 Page 3C-13

Service Procedures
NOTE: Use caution when separating the housing. The lower housing may be completely filled with fuel.
49141
6. Carefully lift the upper housing to access the power wire connections.
7. Disconnect the upper housing power wires from the fuel pump connectors and remove the Oring.
a - Power wires
b - Oring
a
49144
NOTE: Some of the internal components may be adhering to the upper housing when separated. Remove the fuel pumps
with an appropriate tool. Use caution not to twist the fuel pumps when removing them. Use a vice grip tool to clamp onto
the manifold webbing and pull the manifold out of the upper housing.
a - Manifold webbing
49318
Page 3C-14 90-8M0082471 JULY 2014

Service Procedures
8. Remove the manifold from the tubes and fuel pumps.
a- Manifold
b- Lift fuel pump
c- Tubes (4)
a d- Highpressure fuel pump
b
d
c 49147
9. Remove the tubes and fuel pumps from the lower housing.
IMPORTANT: If the fuel pumps are difficult to remove, use an appropriate tool to extract them. Use caution not to twist the
fuel pumps when removing.
a - Fuel tube (2)

b - Water tube (2)
a
b
49150
10. Remove the seal grommets from the manifold.
a - Highpressure fuel pump seal grommet

b - Fuel lift pump seal grommet
a
b
49155
90-8M0082471 JULY 2014 Page 3C-15

Service Procedures
11. Remove three Orings and a spacer from the manifold.
a - Orings
b b - Spacer on fuel pressure regulator
a
49156
12. Carefully spread the retainers and remove the fuel pressure regulator.
IMPORTANT: Use extreme care not to spread the retainers excessively. Spreading the retainers excessively will cause the
retainer to break off the manifold.
13. Remove the Oring and spacer from the fuel pressure regulator.
a - Oring
b - Spacer
a
b
49158
14. Inspect the inside of the upper and lower housings for seal grommets and remove them.
49162
15. Remove the fuel pump wire harness seal grommet from the upper housing by pushing on the seal grommet from the
outside of the upper housing with a blunt tool.
FSM Assembly
1. Install the Orings onto the water tubes and fuel tubes.
Page 3C-16 90-8M0082471 JULY 2014

Service Procedures
2. Lubricate the Orings on the tubes with 24C with PTFE.
a
a - Orings
b - Water tube
c - Fuel tube
c
49167
3. Install the fuel tubes into the lower housing.
49168

95 2-4-C with PTFE O-rings 92-802859A 1
4. Install the water tubes.
b a - Water tube
a b - Fuel tube
49199
90-8M0082471 JULY 2014 Page 3C-17

Service Procedures
5. Install the seal grommet halfway onto the highpressure fuel pump outlet.
49206
6. Lubricate the seal grommet with 24C with PTFE and install the highpressure fuel pump into the lower housing so the
wires are between the webbing and the water tube.
49213
49211
Wires between webbing Close-up view without tube installed

95 2-4-C with PTFE Seal grommet 92-802859A 1
7. Install the seal grommet onto the fuel lift pump and lubricate with 24C with PTFE.
49214

95 2-4-C with PTFE Seal grommet 92-802859A 1
8. Install the fuel lift pump into the lower housing so the outlet port of the pump faces towards the center of the FSM.
9. Install the seal grommet halfway onto the outlet port of the fuel lift pump.
10. Install the seal grommet onto the highpressure fuel pump.
Page 3C-18 90-8M0082471 JULY 2014

Service Procedures
11. Lubricate both seal grommets with 24C with PTFE.
a - Fuel lift pump seal grommet

a b - Highpressure fuel pump seal grommet
49217

95 2-4-C with PTFE Both seal grommets 92-802859A 1
12. Install two Orings onto the manifold.
13. Verify that the hole in the manifold is open and that no debris partially blocks the hole.
IMPORTANT: Use only appropriate solvents and compressed air to remove debris which may be blocking the hole. Do not
use wire or any ridged material that may damage the hole.
a a - Hole in manifold
b - Orings
49165
14. Carefully install the manifold while aligning the fuel pumps and tubes. Verify that the manifold is seated on the fuel pumps.
Ensure that the fuel pump wires are not binding between the water tube and the fuel pump.
a - Manifold seated on fuel pump

b - Wires are not binding
a
b 49223
15. Verify that the spacer is installed onto the fuel pressure regulator.
90-8M0082471 JULY 2014 Page 3C-19

Service Procedures
16. Verify that the fuel pressure regulator filter is clear of debris.
NOTE: The fuel pressure regulator filter is not a serviceable part, but can be cleared of debris with a mild solvent and
lowpressure compressed air.
17. Install the Orings onto the fuel pressure regulator and lubricate them with 24C with PTFE.
b a - Spacer
c b - Filter
c - Orings
a
49164

95 2-4-C with PTFE Fuel pressure regulator O-rings 92-802859A 1
18. Install the fuel pressure regulator onto the manifold.
19. Install the spacer and Oring onto the fuel pressure regulator.
a a - Oring
b b - Spacer
49225
20. Install the seal grommet halfway onto the manifold.

21. Insert the red wire harness connector onto the fuel lift pump positive terminal.
a - Red wire
b - Seal grommet
b
49226
22. Install the Oring onto the upper housing.

23. Install new Orings onto the fuel pump wire harness seal grommet. Verify that the blue Oring is installed on the upper
groove of the seal grommet. Lubricate the Orings with 24C with PTFE.
Page 3C-20 90-8M0082471 JULY 2014

Service Procedures
24. Pull on the wire harness to seat the seal grommet into the upper housing. A gentle push on the seal grommet on the inside
of the housing with a blunt tool will ensure it is properly seated.
a a - Upper housing Oring

b - Blue Oring
b c - Second Oring on seal grommet
c
49231

25. Connect the red wire from the upper housing to the positive terminal on the fuel lift pump.
26. Connect the black wire from the upper housing to the negative terminal on the fuel lift pump.
27. Connect the highpressure fuel pump black wire to the terminal on the fuel lift pump.
28. Lubricate all the visible Orings and seal grommets with 24C with PTFE.
a - Black wires
b - Red wires
a b
49234

95 2-4-C with PTFE O-rings and seal grommets 92-802859A 1
90-8M0082471 JULY 2014 Page 3C-21

Service Procedures
29. Verify that the wires will not become pinched and install the upper housing.
49237
30. Carefully push the upper housing into the lower housing until there is no gap between the upper and lower housing.
IMPORTANT: If the gap between the upper and lower housing cannot be closed, the wires may be pinched or a seal
grommet is not properly aligned.
31. Install the screws and tighten the screws to the specified torque.
a - No gap
b - Screw (4)
a
49240

Screw 10 88.5
32. Install a 15.7 mm metal hose clamp onto the highpressure hose and install the hose onto the FSM upper housing. Use the
hose clamp tool to secure the hose to the FSM.
56209
Page 3C-22 90-8M0082471 JULY 2014

Service Procedures
FSM Installation
1. Install the FSM mounting bracket loosely onto the FSM.
2. Install the FSM into the grommet on the adapter plate from below.
3. Secure the FSM to the driveshaft housing with the M6 x 25 flange head screw. Tighten the screw to the specified torque.

Screw (M6 x 25) 10 88.5
4. Tighten the FSM mounting bracket screw to the specified torque.

Screw (M8 x 30) 27 20
5. Push the fuel hose onto the FSM far enough to lock it in place.
6. Install the water hose to the fitting on the FSM and secure with a cable tie.
a a- Cable tie
b b- Fuel supply hose
c- Water hose
e d- FSM mounting bracket screw
e- Screw securing the FSM mounting bracket to the driveshaft housing
d
55058
7. Install the cooling water supply hose onto the FSM and secure with a cable tie.
c a- Manifold pressure reference line (removed)

b- FSM
c- Cooling water supply hose
d- Cable tie
b d
a
55052
8. Connect the manifold pressure reference line to the FSM.
54899
90-8M0082471 JULY 2014 Page 3C-23

Service Procedures
9. Ensure that the inline filter is installed into the end of the fuel rail.
a - Fuel injector
b - Fuel rail
a b
55859
10. Install a 16.2 mm metal hose clamp onto the highpressure fuel line. Install the highpressure fuel line to the fuel rail. Use
the clamp tool to secure the hose to the rail.
a - Fuel rail
a
b
c
54898

11. Connect the fuel pump harness connector to the engine harness connector and secure the fuel pump harness connector to
the fuel rail with a cable tie.
a - Fuel rail
c - Cable tie
a
b
c
54897
Page 3C-24 90-8M0082471 JULY 2014

Service Procedures
12. Install the idle exhaust muffler onto the adapter plate by pressing it down onto the adapter plate.

b - Adapter plate
b
54893
13. Install the remote control harness, fuel line, throttle, and shift cables.
14. Connect the battery cables.
15. Purge the fuel supply module and check for leaks. Refer to Section 3B Fuel Supply Module Priming Procedure.
16. Install the lower cowls. Refer to Section 5A Lower Cowl.
90-8M0082471 JULY 2014 Page 3C-25

Service Procedures
Notes:
Page 3C-26 90-8M0082471 JULY 2014

Emissions
Fuel Systems
Section 3D - Emissions
Table of Contents
3
Exhaust Emission Standards.............................................3D-2 Dealer Responsibility..................................................3D-3
What Are Emissions?................................................. 3D-2 Owner Responsibility..................................................3D-3
Hydrocarbons HC.................................................... 3D-2 Exceptions.................................................................. 3D-3
Carbon Monoxide CO.............................................. 3D-2
Oxides of Nitrogen NOx...........................................3D-2
EPA Emission Regulations.........................................3D-3
Manufacturer's Certification Label..................................... 3D-3
D
Controlling Emissions................................................. 3D-2 Service Replacement EPA Decal...................................... 3D-4
Stoichiometric (14.7:1) Air/Fuel Ratio.........................3D-2 Removal..................................................................... 3D-4
Emissions Information....................................................... 3D-2 Date Code Identification............................................. 3D-4
Manufacturer's Responsibility.....................................3D-2 Installation.................................................................. 3D-4
90-8M0082471 JULY 2014 Page 3D-1

Emissions
Exhaust Emission Standards

Through the Environmental Protection Agency (EPA), the federal government has established exhaust emissions standards for
all new marine engines sold in the U.S.
What Are Emissions?

Emissions are what comes out of the exhaust system in the exhaust gas when the engine is running. They are formed as a
result of the process of combustion or incomplete combustion. To understand exhaust gas emissions, remember that both air
and fuel are made of several elements. Air contains oxygen and nitrogen among other elements; gasoline contains mainly
hydrogen and carbon. These four elements combine chemically during combustion. If combustion were complete, the mixture
of air and gasoline would result in these emissions: water, carbon dioxide and nitrogen, which are not harmful to the
environment. But combustion is not usually complete. Also, potentially harmful gases can be formed during and after
combustion.
All marine engines must reduce the emission of certain pollutants, or potentially harmful gases, in the exhaust to conform with
levels legislated by the EPA. Emissions standards become more stringent each year. Standards are set primarily with regard to
three emissions: hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx).
Hydrocarbons HC
Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned during combustion in combination with
oxygen. But they are not totally consumed. Some pass through the combustion chamber and exit the exhaust system as
unburned gases known as hydrocarbons.
Carbon Monoxide CO
Carbon is one of the elements that make up the fuel burned in the engine along with oxygen during the combustion process. If
the carbon in the gasoline could combine with enough oxygen (one carbon atom with two oxygen atoms), it would come out of
the engine in the form of carbon dioxide (CO2). CO2 is a harmless gas. But carbon often combines with insufficient oxygen
(one carbon atom with one oxygen atom). This forms carbon monoxide, CO. Carbon monoxide is the product of incomplete
combustion and is a dangerous, potentially lethal gas.
Oxides of Nitrogen NOx

NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that makes up the air going into the
engine. Under extremely high temperatures it combines with oxygen to form oxides of nitrogen (NOx). This happens in the
engine's combustion chambers when temperatures are too high. NOx itself is not harmful, but when exposed to sunlight it
combines with unburned hydrocarbons to create the visible air pollutant known as smog. Smog is a serious problem in
California as well as many other heavily populated areas of the United States.
Controlling Emissions
There are two principle methods of reducing emissions from a marine engine. The first method is to control the air/fuel ratio that
goes into the combustion chamber. The second is to control the time when this air/fuel mixture enters the combustion chamber.
Timing is important, to prevent any unburned mixture from escaping out of the exhaust port.
Stoichiometric (14.7:1) Air/Fuel Ratio

In the search to control pollutants and reduce exhaust emissions, engineers have discovered that they can be reduced
effectively if a gasoline engine operates at an air/fuel ratio of 14.7:1. The technical term for this ideal ratio is stoichiometric. An
air/fuel ratio of 14.7:1 provides the best control of all three elements in the exhaust under almost all conditions. The HC and CO
content of the exhaust gas is influenced significantly by the air/fuel ratio. At an air/fuel ratio leaner than 14.7:1, HC and CO
levels are low, but with a ratio richer than 14.7:1 they rise rapidly. It would seem that controlling HC and CO by themselves
might not be such a difficult task; the air/fuel ratio only needs to be kept leaner than 14.7:1. However, there is also NOx to
consider.
As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combustion temperatures raise the NOx
content of the exhaust. But, enrichening the air/fuel ratio to decrease combustion temperatures and reduce NOx also increases
HC and CO, as well as lowering fuel economy. So the solution to controlling NOx as well as HC and CO is to keep the air/
fuel ratio as close to 14.7:1 as possible.
Emissions Information
Manufacturer's Responsibility
Beginning with 1998 model year engines, manufacturers of all marine propulsion engines must determine the exhaust emission
levels for each engine horsepower family and certify these engines with the United States Environmental Protection Agency
(EPA). A certification decal/emissions control information label, showing emission levels and engine specifications directly
related to emissions, must be placed on each engine at the time of manufacture.
Page 3D-2 90-8M0082471 JULY 2014

Emissions
Dealer Responsibility
When performing service on all 1998 and newer outboards that carry a certification, attention must be given to any adjustments
that are made that affect emission levels.
Adjustments must be kept within published factory specifications.
Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within
the prescribed certification standards.
Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their
predetermined factory specifications.
Exceptions include manufacturer's prescribed changes, such as that for altitude adjustments.
Owner Responsibility
The owner/operator is required to have engine maintenance performed to maintain emission levels within prescribed
certification standards.
The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to
exceed their predetermined factory specifications.
Exceptions
Carburetor jets may be changed for high altitude use in accordance with factory recommendations.
Single engine exceptions may be allowed with permission from the EPA for racing and testing.
EPA Emission Regulations

All 1998 and newer outboards manufactured by Mercury Marine are certified to the United States Environmental Protection
Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This
certification is contingent on certain adjustments being set to factory standards. For this reason, the factory procedure for
servicing the product must be strictly followed and, whenever practicable, returned to the original intent of the design.
The responsibilities listed above are general and are 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 locations:
VIA U.S. POSTAL SERVICE:
Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460,
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources Engine Programs and Compliance Division Engine Compliance Programs Group (6403J)
501 3rd St. NW
Washington, DC 20001,
EPA INTERNET WEB SITE: http:/www.epa.gov/omswww
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.
EMISSION CONTROL
a INFORMATION
f a- Idle speed
THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA
g b- Engine horsepower
b
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE,
SPECIFICATIONS, AND ADJUSTMENTS c- Piston displacement
c IDLE SPEED (in gear): FAMILY:
h d- Engine power in kilowatts
hp L HC+NOx:FEL: g/kWh
d e- Date of manufacture
kw CO FEL: g/kWh
i
f- Family number
SPARK PLUG:
GAP:
e LOW PERM/HIGH PERM: j g- Regulated emissions limit for the engine family
43210
h- Regulated emissions limit for the engine family
i- Recommended spark plug and gap
j- Percent of fuel line permeation
90-8M0082471 JULY 2014 Page 3D-3

Emissions
Service Replacement EPA Decal

IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine outboards have a visible and legible
emission certification decal. If this decal is missing or damaged, contact Mercury Marine Service for a replacement.
Removal
Remove all remaining pieces of the damaged or illegible decal. Do not install the new decal over a damaged old decal. Use a
suitable solvent to remove any traces of the old decal adhesive from the display location.
NOTE: If the original decal surface is in good condition, it is acceptable to clean the surface and apply the new decal over the
original.
Date Code Identification

Cut and remove a "V" notch through the month of engine manufacture before installing the new decal. The month of
manufacture can be found on the old decal. If the decal is missing or the date code illegible, contact Mercury Marine Technical
Service for assistance.
Emission Control a - "V" notch

Information b - Month of
manufacture
THIS ENGINE CONFORMS TO (YEAR) CALIFORNIA AND U.S. EPA
REFER TO OWNERS MANUAL FOR MAINTENANCE,
SPECIFICATIONS, AND ADJUSTMENTS
IDLE SPEED (in gear): XXX RPM FAMILY: -----.XXXXXX
XXX HP XXXX cc FEL: XX.XXXX g/kWh
TIMING (IN DEGREES): XXXXXXXXX
PART NO. SPARK PLUG: XXXXXXXX
37-XXXXXX GAP: X.X MM (X.X IN.)
COLD VALVE INTAKE: 0.XX - 0.XX MM
CLEARANCE (mm) EXHAUST: 0.XX - 0.XX MM
JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC b
a 11184
Installation
Apply the decal on a clean surface in the original factory location.
Page 3D-4 90-8M0082471 JULY 2014

Cylinder Block/Crankcase
Powerhead
Section 4A - Cylinder Block/Crankcase
Table of Contents
Cylinder Block/Crankcase Specifications...........................4A-2 Measuring Connecting Rod ..................................... 4A-28
Crankshaft, Connecting Rods, and Pistons....................... 4A-4 Measuring Crankshaft...............................................4A-29
Cylinder Block Components...............................................4A-6 Oil Pump .................................................................. 4A-30
Exhaust Manifold............................................................... 4A-8 Powerhead Assembly...................................................... 4A-32
Dressed Powerhead Removal ........................................ 4A-10 Cylinder Block Galley Plug Installation..................... 4A-32
Removing Powerhead Components................................ 4A-15
Removing Powerhead Components Individually...... 4A-15
Crankshaft Installation.............................................. 4A-33
Piston/Connecting Rod Assembly............................ 4A-38 4
Removing Powerhead Components as an Assembly
.............................................................................. 4A-16
Piston Ring Installation............................................. 4A-39
Connecting Rod Bearing Grade Selection................4A-40 A
Powerhead Disassembly ................................................ 4A-22 Piston Connecting Rod Assembly Installation.......... 4A-42
Cylinder Head Removal............................................4A-22 Crankshaft Seal Installation...................................... 4A-44
Cylinder Block Disassembly and Crankshaft Removal Cylinder Head Installation.........................................4A-46
.............................................................................. 4A-24 Oil Pump Installation.................................................4A-52
Cleaning, Inspection, and Repair.....................................4A-26 Installing Powerhead Components.................................. 4A-54
Powerhead Preassembly Cleaning Installing Powerhead Components as an Assembly
Recommendations................................................ 4A-26 .............................................................................. 4A-54
Measuring Cylinder Bore.......................................... 4A-26 Powerhead Installation onto the Midsection.................... 4A-60
Measuring Piston...................................................... 4A-26 Engine Breakin Procedure..............................................4A-66
90-8M0082471 JULY 2014 Page 4A-1


Compression ratio 10:1
Standard bore finished hone 90.00 mm (3.543 in.)
Stroke 82.00 mm (3.228 in.)
Cylinder deck
Crankcase deck
Cylinder bore maximum taper (service) 0.030 mm (0.0011 in.)
Cylinder bore maximum out of round (service) 0.050 mm (0.0019 in.)
A 52.98852.996 mm (2.08622.0864 in.)
Cylinder block main bearing journal
B 52.99753.004 mm (2.08652.0867 in.)
(letter)
C 53.00553.012 mm (2.08682.0870 in.)
Crankshaft main bearing journal A 47.99348.001 mm (1.88951.8898 in.)

(letter) B 47.98547.993 mm (1.88921.8898 in.)
C 43.99244.000 mm (1.73201.7323 in.)
Crankshaft connecting rod journal
D 43.98443.992 mm (1.73171.7320 in.)
Crankshaft end play 0.05080.3048 mm (0.0020.012 in.)
Crankshaft runout 0.025 mm (0.0009 in.)
Crankshaft main bearing oil clearance 0.0500.084 mm (0.00190.0033 in.)
Connecting rod piston pin bore diameter 20.01620.026 mm (0.78810.7884 in.)
Journal grade "I" 47.00047.008 mm (1.85041.8507 in.)
Connecting rod crankshaft pin diameter
Journal grade "0" 47.00847.016 mm (1.85071.8510 in.)
Connecting rod bearing oil clearance 0.0310.059 mm (0.00120.0023 in.)
Piston skirt standard diameter 89.94289.952 mm (3.54103.5414 in.)
Minimum 0.048 mm (0.0018 in.)
Piston to cylinder clearance
Maximum 0.073 mm (0.0028 in.)
Piston pin bore diameter 19.99620.011 mm (0.78730.7878 in.)
Piston pin diameter 19.99620.001 mm (0.78730.7874 in.)
First 1.011.03 mm (0.0398 0.0405 in.)
Piston ring groove width Second 1.011.03 mm (0.0398 0.0405 in.)
Third 2.012.03 mm (0.07920.0799 in.)
First 0.970.99 mm (0.03820.0389 in.)
Piston ring thickness
Second 0.970.99 mm (0.03820.0389 in.)
First 0.020.06 mm (0.00070.0023 in.)
Piston ring side clearance
Second 0.020.06 mm (0.00070.0023 in.)
First 0.270.37 mm (0.01070.0145 in.)
Piston ring end gap Second 0.420.62 mm (0.01660.0244 in.)
Third (lower ring only) 0.20.7 mm (0.00790.0275 in.)
Page 4A-2 90-8M0082471 JULY 2014


Oil pump seal lips
Extreme Grease Crankshaft seal lip 8M0071842
Oil pump seal lip and oil pump gerotor drive flats
Loctite 567 PST Pipe Water pump indicator hose plastic fitting threads, block water
9 92-809822
Sealant temperature sensor threads, oil pressure sensor threads
Starter motor ground cable screw and cable end
Starter solenoid activation lead connection
Tensioner guide screw threads
66 Loctite 242 Threadlocker Stator mounting screws 92-809821
Throttle cam screw threads
Smooth side of center main thrust bearing
95 2-4-C with PTFE 92-802859A 1
Crankshaft O-ring
4-Stroke 10W-30 Outboard Oil pump
110 92-858045K01
Oil Camshaft gear screw threads and flange head
135 Three Bond 1217F Crankcase cover seal area 92-858005K02
Piston pin
136 Lubriplate SPO 255 Rod cap screw threads and under the screw head Obtain Locally
Timing chain tensioner assembly
Piston ring grooves
Synthetic Blend 4-Stroke Piston and rings
139 92-8M0078629
Outboard Oil 25W-40 Cylinder bore
Flange head of shoulder screw
Special Tools

14869
Holds and/or turns the flywheel while making engine repairs, also used to torque
the flywheel or the engine coupler.
4738
Crankshaft retainer and connecting rod

Part number not available at time of printing
guides
Retains the crankshaft and guides the connecting rods onto the crankshaft
during powerhead assembly.
56212

Used to clamp high pressure (Oetiker ) hose clamps. Part of Clamp Tool Kit
39648 (91803146A4).
90-8M0082471 JULY 2014 Page 4A-3

Crankshaft, Connecting Rods, and Pistons
6 3
7 4
8
12 5
9
2
11
10
55133
Page 4A-4 90-8M0082471 JULY 2014

Crankshaft, Connecting Rods, and Pistons

Torque
1 4 Piston assembly
2 4 Piston ring set
3 4 Connecting rod
First 10 88.5
4 8 Rod cap screw Second 25 18.4
Final Turn an additional 90
5 4 Connecting rod bearing set
6 1 Retaining ring
7 1 Crankshaft seal
8 1 Spacer
9 1 Crankshaft
10 1 Oring seal
11 5 Main bearing set
12 1 Woodruff key
90-8M0082471 JULY 2014 Page 4A-5

Cylinder Block Components
3 7
6
3
7
4
16
9 3
8
10
11
15
14
13
12
55132
Page 4A-6 90-8M0082471 JULY 2014

Cylinder Block Components

Torque
1 1 Cylinder block
2 1 Cylinder block cover
3 4 Dowel pin
First 20 177
4 10 Screws (M10 x 110) Second 40 29.5
5 1 Dipstick
6 1 Plug (18 mm) 22 194.7
7 2 Plug (10 mm) 9 79.7
8 1 Plug (30 mm) 55 40.5
9 10 Screw (M8 x 50) 35 15.8
10 1 Oil pump assembly
11 4 Screw (M6 x 45) 10 88.5
12 1 Oil pickup tube
13 1 Metal hose clamp (39.6 mm)
14 1 Oil pickup hose
15 1 Metal hose clamp (34.6 mm)
16 1 Thrust bearing
90-8M0082471 JULY 2014 Page 4A-7

Exhaust Manifold
4
3 2
3 2
3
2
55137
Page 4A-8 90-8M0082471 JULY 2014

Exhaust Manifold
Torque
1 1 Exhaust manifold
2 3 Plug (18mm) 22 194.7
3 2 Oring
4 1 Gasket
First 15 132.7
5 9 Screw (M8 x 60)
Final 28 20.6
90-8M0082471 JULY 2014 Page 4A-9

Dressed Powerhead Removal

! WARNING
1. Disconnect all batteries from the engine.

2. Remove the upper and lower cowls. Refer to Section 5A Lower Cowl Removal.
3. Remove the throttle and shift cables, fuel line, and remote control harness.
4. Remove the flywheel cover by lifting up and away from the grommet seats.
5. Drain the oil from the engine. Refer to Section 1B Changing Engine Oil.
6. Remove the idle exhaust muffler from the adapter plate by lifting it up and away from the adapter plate.

b - Adapter plate
b
54893
7. Cut the cable tie securing the fuel pump connector to the fuel rail.
8. Disconnect the fuel pump connector from the engine harness.
a - Fuel rail
c - Cable tie
a
b
c
54897
9. Release the fuel pressure on the fuel rail. Refer to Section 3C Fuel Rail Removal and Disassembly.
! CAUTION
Page 4A-10 90-8M0082471 JULY 2014

10. Remove the 16.2 mm metal hose clamp securing the highpressure fuel line to the fuel rail. Remove the highpressure fuel
line from the fuel rail.
a - Fuel rail
c - Highpressure fuel line
a
b
c
54898
11. Disconnect the manifold pressure reference line from the fuel supply module (FSM).
54899
12. Cut the cable tie securing the hose to the water pump indicator fitting. Remove the hose from the water pump indicator
fitting.
13. Remove the M6 x 25 screw securing the powerhead water dump hose fitting to the adapter plate.
a - Cable tie securing the hose to the water pump indicator

b fitting
b - Water dump hose fitting
c - M6 x 25 screw
c
54900
14. Remove the water dump hose fitting from the adapter plate.
IMPORTANT: After removing the water dump hose fitting from the adapter plate, cover the opening with a piece of tape.
90-8M0082471 JULY 2014 Page 4A-11

15. Remove the four powerhead mounting screws at the aft end of the powerhead.
54901
16. Remove the nut and washer securing the shift link to the shift shaft.
a a - Nut
b - Washer
c b c - Shift link
54903
17. Disconnect the fuel supply hose connector at the fuel filter outlet port.
a - Fuel supply hose connector at the fuel filter outlet port

b - Fuel filter
a b
54905
18. Cut the cable tie securing the water strainer hose to the fitting behind the exhaust manifold. Remove the hose.
19. Remove the spark plug wires from the spark plugs. Remove the spark plug wires from the retainers on the cam cover and
the exhaust manifold.
20. Remove the spark plug wire retainer from the exhaust manifold.
Page 4A-12 90-8M0082471 JULY 2014

21. Remove the six screws securing the voltage regulator to the exhaust manifold.
a- Spark plug wires

b- Retainer on the cam cover
c- Fitting behind the exhaust manifold (hose removed)
a
d- Retainer on the exhaust manifold
e- Exhaust manifold
f- Voltage regulator
a
f
e a
c
d a
54906
22. Remove the six screws securing the exhaust manifold to the cylinder head.
a a a - Exhaust manifold screw (6)

b - Voltage regulator (removed)
a
b
54909
23. Rotate the exhaust manifold away from the cylinder head, then lift the exhaust manifold upwards to remove it from the
adapter plate.
90-8M0082471 JULY 2014 Page 4A-13

24. Remove the three port side screws securing the powerhead to the adapter plate.
54912
25. Remove the four starboard side screws securing the powerhead to the adapter plate.
54914
26. Remove the engine oil dipstick.

27. Install the flywheel puller/lifting ring and secure with the screws. Tighten the screws to the specified torque.
NOTE: It may be necessary to grasp the bottom of the cam cover and pull up to remove the powerhead assembly from the
adapter plate.
54915

Screws 27 20
Page 4A-14 90-8M0082471 JULY 2014

! CAUTION
Improper lifting during removal or installation of the engine can cause injury or damage to engine components. Use a hoist,
lifting arm, or other approved lifting device. Do not allow the lifting device to hook or compress any engine components.
28. Use a suitable engine hoist to remove the powerhead from the driveshaft housing.
29. Remove the metal hose clamp securing the oil pickup tube to the oil pump. Remove the hose from the oil pump.
a - Metal hose clamp securing the oil pickup tube
48074
30. Clean the oil sump to remove any traces of debris or contaminated engine oil.
Removing Powerhead Components

Removing Powerhead Components Individually
This section explains where in this manual to look for information about removing engine components individually.
If removing engine components for purposes of powerhead maintenance or repair (such as internal engine service), refer to
Removing Powerhead Components as an Assembly.
To remove this component individually... Refer to this section...

Coil/electrical plate 2A
Engine control module (ECM) 2A
Flywheel/stator 2A
Fuel rail 3C
Fuel supply module (FSM) 3C
Fuel injectors 3C
Fuel filter 1B
Fuel rail 3C
Manifold absolute pressure (MAP) sensor 2A
Starter motor 2B
Starter solenoid 2B
Throttle position sensor (TPS) 3B
Throttle body 3C
Oil pump 4C
Oil pressure sensor 2B
Water temperature sensor 2B
Water pressure sensor 2B
90-8M0082471 JULY 2014 Page 4A-15

Removing Powerhead Components as an Assembly

Wire Harness and Engine Control Module (ECM) Removal
1. Cut the cable tie securing the manifold air temperature (MAT) sensor harness connector to the sensor. Disconnect the
engine harness connectors from the throttle position sensor (TPS), oil pressure sender, MAT sensor, and idle air control
(IAC).
a- Cable tie
b- MAT
c c- TPS
d- Oil pressure sender
e- IAC
b
a d
2. Disconnect the harness connector from the manifold absolute pressure (MAP) sensor. Cut the cable ties securing the
wiring harness as shown. Guide the harness past the throttle body.
a a - Cable ties
b - MAP sensor connector
54926
3. Cut the six cable ties securing the engine harness to the starboard side of the powerhead.
Page 4A-16 90-8M0082471 JULY 2014

4. Disconnect the engine harness connectors from the fuel injectors. Disconnect the shift position switch connector.
a - Cable ties
a
b - Fuel injectors
c - Shift position switch
b
a
b
c
a
b
a
b
a
54927
5. Disconnect the engine harness connectors from the water pressure sensor, crankshaft position sensor, and water
temperature sensor (optional).
a - Water temperature sensor connector

b - Crankshaft position sensor connector
b c
c - Water pressure sensor connector (optional)
54929
6. Guide the engine harness out from under the thermostat dump hose and crankcase ventilation hose.
7. Remove the electrical covers from the port side and the front of the powerhead. Cut the four cable ties as shown
8. Remove the screw securing the engine wire harness grounds to the cylinder block. Disconnect the stator harness
connector from the engine harness.
9. Remove the upper coil plate mounting screw.
a- Stator harness connector

d
b- Upper coil plate mounting screw
c- Screw securing the engine wire harness grounds
d- Cable ties (4)
b
d
a
c
54930
90-8M0082471 JULY 2014 Page 4A-17

10. Remove the lower coil plate mounting screw.
a - Lower coil plate mounting screw

b - Engine control module (ECM)
b
54935
11. Disconnect the starter solenoid activation lead from the starter solenoid.
12. Disconnect the ECM harness connector from the ECM.
13. Remove the three screws securing the electrical plate to the crankcase cover. Remove the electrical plate, coil plate, and
harness as an assembly.
a - Screws securing the electrical plate

b - Starter solenoid activation lead
c - ECM harness connector
b
a
54936
14. Remove the three screws securing the ECM to the crankcase cover. Remove the ECM and retain the Jclip.
a - Screws (3)
b b - Jclip
54937
Starter Motor, Shift Bracket, Intake Manifold, Thermostat Housing, and Sensors
1. Remove the screw securing the starter motor ground cable to the cylinder block.
Page 4A-18 90-8M0082471 JULY 2014

2. Remove the three screws securing the starter motor assembly to the cylinder block.
a - Screws (3)
b - Screw securing the starter motor ground cable
54964
3. Remove the three screws securing the throttle/shift cable bracket to the cylinder block. Remove the throttle/shift cable
bracket.
4. Remove the screw securing the throttle cam to the cylinder block.
5. Remove the two screws securing the drip tray to the cylinder block.
a - Screw securing the throttle cam to the cylinder block

b - Screws securing the drip tray to the cylinder block (2)
c - Screws securing the throttle/shift cable bracket to the
cylinder block
a b
54966
6. Remove the 10 screws securing the intake manifold to the cylinder block. Remove the intake manifold.
Hoses not shown for visual clarity

a - Screws securing the intake manifold (10)
a
a
54968
90-8M0082471 JULY 2014 Page 4A-19

7. Remove the metal hose clamp to remove the thermostat dump hose from the thermostat housing, if required. Remove the
two screws securing the thermostat housing to the cylinder head. Cut the cable tie and remove the water pump indicator
hose from the fitting on the cylinder head.
c d a- Water pump indicator hose

b- Metal hose clamp
b e
d c- Cable tie
d- Fitting
a
e- Screws securing the thermostat housing (2)
f- Thermostat dump hose
f
54973
8. Remove the metal hose clamp securing the crankcase ventilation hose to the cam cover, if required.
NOTE: For most engine service procedures, the crankcase ventilation hose can remain attached to the cam cover. It only
needs to be removed if the crankcase ventilation hose requires replacement. Ensure that no foreign debris enters the
hose.
a - Metal hose clamp

b - Crankcase ventilation hose
56269
9. Remove the remaining sensors and the water pump indicator hose fitting from the cylinder block.
a- Screws securing the crankshaft position sensor

b- Water pressure sensor (optional)
a c- Water temperature sensor
e- Water pump indicator hose fitting
b
e c
d 54976
Flywheel Removal
The flywheel has three threaded hoses that are used with the Flywheel Puller/Lifting Ring to remove the flywheel. These three
holes can also be used with the Flywheel Puller/Lifting Ring to remove or install the complete outboard on a boat.
Page 4A-20 90-8M0082471 JULY 2014

1. Hold the flywheel with the Flywheel Holding Tool. Loosen the flywheel screw four turns out from a light seat.
a - Breaker bar with M30 socket

b - Flywheel holding tool
a
b
55012

2. Install the flywheel puller base onto the flywheel with the three flanged head screws. Tighten the screws to the specified
torque.

Flanged head screws securing the flywheel puller base 27 20
3. Thread the flywheel puller adapter into the flywheel puller base until it bottoms out.
4. Thread the flywheel puller bolt into the flywheel puller adapter.
5. Tighten the flywheel puller bolt until the flywheel is loose, then remove the flywheel puller, flywheel screw and washer, and
the flywheel.
c a- Flywheel puller base

b b- Flywheel puller adapter
d c- Flywheel puller bolt
d- Flanged head screws (3)
a
55017
Stator Removal
1. Loosen each stator mounting screw onequarter turn in a crossing pattern.
2. Remove the six stator mounting screws. Remove the stator.
a - Stator mounting screws (6)
55019
90-8M0082471 JULY 2014 Page 4A-21

Powerhead Disassembly
Cylinder Head Removal
1. Remove the 13 screws securing the cam cover to the cylinder head.
54981
2. Remove the two screws securing the timing chain tensioner cover.
NOTE: The timing chain tensioner will exert a constant force when removing the cover screws.
55002
3. Secure the camshaft hex with a wrench and rotate the camshaft so the camshaft gear timing mark is at the 9 o'clock
position.
NOTE: If the camshaft gear timing mark cannot be identified, the camshaft gear pin can also be used for the 9 o'clock
position.
4. Remove the camshaft gear retaining screw and remove the gear.
Page 4A-22 90-8M0082471 JULY 2014

IMPORTANT: The camshaft gear retaining screw is lefthand thread.
a - Camshaft gear timing mark

b - Camshaft gear pin
c - Camshaft gear retaining screw (lefthand thread)
a
b c
55376
5. Remove the two M6 x 40 screws at the bottom of the cylinder head.
55413
6. Loosen the M10 x 110 screws 1/4 turn in the sequence shown. Perform the 1/4 turn sequence twice, and then remove the
screws. Remove the cylinder head.
4 8 10 6
2
3 7 9 5 1 55435
90-8M0082471 JULY 2014 Page 4A-23

Cylinder Block Disassembly and Crankshaft Removal

1. Remove the four screws securing the oil pump to the cylinder block.
55594
2. Remove the screws securing the chain guides and remove the chain guides.
3. Remove the chain from the crankshaft.
55595
4. Loosen the 12 M8 x 50 perimeter screws and the ten M10 x 110 main bearing screws 1/4 turn each in the sequence
shown, then remove the screws.
4 8 10 6
2
14 18 20 16 12
13 17 19 15 11
1 55597
3 7 9 5
Page 4A-24 90-8M0082471 JULY 2014

5. Use the pry locations on both sides of the powerhead to break the crankcase cover seal and remove the bedplate.
55598
6. Use a clean cloth and a mild solvent to remove any oil from the connecting rod caps.
7. Identify each connecting rod cap location with indelible ink.
8. Loosen the rod cap screws 1/4 turn each before removing them completely. Remove the rod cap. Verify that the bearing is
on the rod cap and not on the crankshaft journal.
a - Identifying marks on connecting

rod caps
b - Connecting rod cap screws (2
each)
a
b
55605
9. Push the connecting rod assembly out of the cylinder block bore and install the connecting rod cap. Secure the cap with
the rod cap screws. Remove the remaining connecting rods and pistons.
10. Remove the crankshaft from the cylinder block. Secure the crankshaft into a fixture so it will not be damaged.
11. Remove the main bearings from the cylinder block and crankcase cover.
IMPORTANT: The bearings are matched sets and cannot be intermixed. Identify where each bearing set was installed.
12. Remove the 18 mm oil galley plug from the top of the cylinder block. Remove the Oring and discard.
13. Remove the 10 mm oil galley plug from near the top of the cylinder block. Remove the Oring and discard.
14. Remove the 30 mm oil galley plug from the bottom of the cylinder block. Remove the Oring and discard.
a - 18 mm oil galley plug

b - 10 mm oil galley plug
c - 30 mm oil galley plug
b
a c
55603
90-8M0082471 JULY 2014 Page 4A-25

Cleaning, Inspection, and Repair

Powerhead Preassembly Cleaning Recommendations
IMPORTANT: Any threaded hole or bolt with threadlocking compound that is contaminated with oil, must be thoroughly cleaned
with a solvent to remove all traces of oil contamination. Failure to remove oil contamination will result in poor threadlocking
compound adhesion.
Prior to assembling the powerhead, all threaded holes on the cylinder head and cylinder block must be cleared of threadlocking
compound dust. Use compressed air to clear threadlocking compound dust.
Wash the cylinder block and crankcase cover with hot soapy water to remove debris and honing compound. Dry the cylinder
block with compressed air. Failure to thoroughly clean the cylinder block of honing compound and/or debris will result in
premature engine failure.
Measuring Cylinder Bore

Measure the cylinder walls for taper, out of round, or excessive ridge at the top of the ring travel. This should be done with a
cylinder bore dial indicator or an inside micrometer. Carefully move the gauge up and down the cylinder bore to determine
taper. Turn the gauge to different points around the cylinder wall to determine the out of round condition.
The measurement for cylinder taper should be taken at three depth locations: 20 mm (0.8 in.), 60 mm (2.4 in.), and 100 mm
(3.9 in.).
a - 100 mm (3.9 in.)

b - 60 mm (2.4 in.)
c - 20 mm (0.8 in.)
c
b
a
3129
Cylinder Bore Specification

Standard finished hone 90.00 mm (3.5433 in.)
Maximum taper (service) 0.030 mm (0.0011 in.)
Maximum out of round (service) 0.050 mm (0.0019 in.)
Measuring Piston
Inspect the piston wall for wear or damage. Replace the piston if necessary.
Piston Diameter
1. Measure the piston at a point 16 mm (0.63 in.) from the bottom, 90 to the piston pin. Replace the piston if it is out of
specification.
a a - Piston skirt diameter

b b - Measure point 16 mm (0.63 in.)
22022
Piston
Skirt diameter 89.94289.952 mm (3.54103.5414 in.)
2. Measure the piston to cylinder clearance. If it is out of specification, examine the piston and cylinder bore further to
determine repair or replacement.
Page 4A-26 90-8M0082471 JULY 2014

The minimum piston to cylinder wall clearance is defined by the formula: Minimum cylinder bore measurement Maximum
piston diameter measurement = Piston to Cylinder Clearance.
Piston to Cylinder Clearance

Minimum clearance 0.048 mm (0.0018 in.)
Maximum clearance 0.073 mm (0.0028 in.)
Piston Ring Groove

Measure the piston ring groove. Replace the piston if it is out of specification.
a - First ring groove

a b - Second ring groove
c - Third ring groove (oil)
b
c 22410
Piston Ring Groove

First "a" 1.011.03 mm (0.03980.0405 in.)
Second "b" 1.011.03 mm (0.03980.0405 in.)
Third "c" 2.012.03 mm (0.07920.0799 in.)
Piston Ring Side Clearance

Measure the first and second piston ring side clearance. The side clearance for the third ring (oil) is not a valid measurement
because of ring movement during the measurement process. Replace the piston rings as a set if they are out of specification.
a a - First ring
b - Second ring
b c - Third ring (oil)
c
48804
Piston Ring Side Clearance

First "a" 0.020.06 mm (0.00070.0023 in.)
Second "b" 0.020.06 mm (0.00070.0023 in.)
Piston Ring End Gap

Measure the piston ring end gap clearance. Replace the piston rings as a set if they are out of specification.
NOTE: The ring must be level for measurement. Use the crown of the piston to push the ring 25.4 mm (1.0 in.) into the bore.
a - 25.4 mm (1.0 in.)
22024
90-8M0082471 JULY 2014 Page 4A-27

Piston Ring End Gap

First 0.270.37 mm (0.01070.0145 in.)
Second 0.420.62 mm (0.01660.0244 in.)
Third (lower oil ring only) 0.20.7 mm (0.00790.0275 in.)
Piston Pin Bore Diameter

Measure the piston pin bore diameter. Replace the piston if it is out of specification.
22025
Piston Pin
Bore diameter 19.99620.011 mm (0.78730.7878 in.)
Piston Pin
Measure the piston pin diameter. Replace the piston pin if it is out of specification.
22026
Piston Pin
Diameter 19.99620.001 mm (0.78730.7874 in.)
Measuring Connecting Rod

1. Secure the connecting rod in a soft jaw vice.
2. Verify the rod cap alignment and tighten the screws in three stages to the specified torque.

First 10 88.5
Rod cap screws Second 25 18.4
Final Turn additional 90
Page 4A-28 90-8M0082471 JULY 2014

3. Measure the small (piston pin) and large (crankshaft journal) ends of the connecting rod.
a a - Crankshaft journal end

b b - Piston pin end
47983
4. Compare the connecting rod journal measurement with the journal code specifications listed in the following chart. If the
connecting rod journal measurement does not match the stamped connecting rod journal code, replace the connecting rod.
a - Stamped connecting rod journal code "I"

b - Stamped connecting rod journal code "0"
a b
0
47985
Connecting Rod
19.99620.011 mm
Piston pin bore
(0.78730.7878 in.)
47.00047.008 mm
Journal code "I"
(1.85041.8507 in.)
47.00847.016 mm
Journal code "0"
(1.85071.8510 in.)
Measuring Crankshaft
Crankshaft Runout
1. Thoroughly clean the crankshaft and inspect bearing surfaces. Replace the crankshaft if bearing surfaces are pitted,
scored, or discolored.
2. Measure runout on all of the main bearing journals. Replace the crankshaft if it is out of specification.
3. Clean the oil holes in the crankshaft.
47987
Crankshaft
Runout limit 0.025 mm (0.0009 in.)
Crankshaft Main Bearing and Crankshaft Journal Measurement

1. Measure the five main bearing journal diameters and record the measurements.
90-8M0082471 JULY 2014 Page 4A-29

2. Measure the crankshaft journal diameters and record the measurements.
a
a - Crankshaft journals
b - Main bearing journals
47988
b
3. Locate the main bearing journal code on the cylinder number one top counterweight. Compare the journal code with your
recorded measurements. If the measurements do not match the journal specifications, replace the crankshaft.
a - Main bearing journal code

b - Crankshaft journal code
a
55613
Crankshaft Journal Specifications

Description Dimension Code
47.99348.001 mm (1.88951.8898 in.) A
Main bearing journal
47.98547.993 mm (1.88921.8894 in.) B
43.99244.000 mm (1.73201.7323 in.) C
Crankshaft journal
43.98443.992 mm (1.73171.7320 in.) D
Oil Pump
Disassembly and Inspection
The oil pump is not a serviceable part, but should be disassembled for inspection when the cylinder head or cylinder block is
repaired. The oil pump should also be disassembled and inspected if the engine was submerged in water.
Page 4A-30 90-8M0082471 JULY 2014

1. Remove the eight screws securing the oil pump cover to the oil pump housing in the sequence shown. Remove the cover.
2 7
3
1 8 55459
2. Remove the inner drive gerotor and outside gerotor.
a a - Inner drive gerotor

b - Outside gerotor
55471
3. Inspect all areas where the gerotors contact each other and where the gerotors contact the oil pump housing and cover.
The contact areas should be smooth without grooves, galling, or evidence of corrosion.
IMPORTANT: A pressure relief valve is incorporated into the oil pump housing. It should never be removed from the
housing to modify the spring pressure. If significant debris was found in the oil pump gerotor area, the oil pump must be
replaced as an assembly.
Assembly
1. Wash the housing, cover, and gerotors with a mild solvent. Use compressed air to dry the components.
2. Inspect the seal lips for damage. Replace as needed. Lubricate the seal lips with Extreme Grease.

Extreme Grease Oil pump seal lips 8M0071842
3. Generously lubricate the gerotors and the areas where the gerotors contact the housing and cover with 4Stroke 10W30
Outboard Oil.

4-Stroke 10W-30
110 Oil pump 92-858045K01
Outboard Oil
4. Install the outside gerotor into the oil pump housing with the dot side up.
90-8M0082471 JULY 2014 Page 4A-31

5. Install the inner drive gerotor.

b - Outside gerotor
55471
6. Align the oil pump cover with the oil pump housing pins and install the oil pump cover.
7. Secure the oil pump cover with eight screws. Tighten the screws to the specified torque in the sequence shown.
7 2
6
8 1 55460

Oil pump cover screws (7) 4 35.4
Powerhead Assembly
Cylinder Block Galley Plug Installation
1. Install new Orings onto the galley plugs.
Page 4A-32 90-8M0082471 JULY 2014

2. Install the galley plugs in their appropriate locations and tighten them to the specified torque.
a - 18 mm oil galley plug

b - 10 mm oil galley plug
c - 30 mm oil galley plug
b
a c
55603

18 mm oil galley plug 22 194.7
Crankshaft Installation
Crankshaft Main Bearing Selection
1. Locate the main bearing code on the starboard side of the cylinder block.
a - Cylinder block main

bearing code
55606
2. Locate the main bearing journal code on the top of the crankshaft.

a
55613
3. Select the main bearing color for each main bearing journal. Refer to the following chart.
90-8M0082471 JULY 2014 Page 4A-33

Crankshaft Journal Code Cylinder Block Code Bearing Color Selection

A A Green
A B Blue
A C White
B A Blue
B B White
B C Orange
Crankshaft Installation
1. Verify that the cylinder block and the crankcase cover main bearing locations are clear of debris and contamination.
2. Verify that the main bearing selection is correct.
3. Install the selected main bearings with the oil groove onto the cylinder block. Install the selected main bearings without the
oil grooves onto the crankcase cover.
IMPORTANT: Each matched bearing set has one bearing half without an oil groove and one with an oil groove, The
bearing half with the oil groove must be installed onto the cylinder block main bearing location. Failure to install the bearing
half with the oil groove onto the cylinder block main bearing location will cause a nolubrication condition for that main
bearing, and will result in catastrophic engine failure.
4. Apply 24C with PTFE to the smooth side of the center main thrust bearings.
a. Install the number four main thrust bearings into the cylinder block. Verify that the smooth surface of the thrust
bearing (without oil grooves) is against the cylinder block.
a - Smooth surface of thrust bearing against cylinder

block
b - Main bearing installed into cylinder block (with oil
groove)
c - Oil grooves on thrust bearing
a
55616
c

95 2-4-C with PTFE Smooth side of center main thrust bearing 92-802859A 1
5. Verify that the locating dowel pins are installed into the crankcase cover.
6. Carefully lower the crankshaft onto the cylinder block main bearings.
Page 4A-34 90-8M0082471 JULY 2014

7. Install a piece of Plastigauge parallel to the crankshaft on the main bearing journals.
48495
8. Install the crankcase cover onto the cylinder block.

IMPORTANT: Do not allow the crankshaft to rotate when checking the bearing clearance with Plastigauge.
9. Install the ten M8 perimeter screws and the ten M10 main bearing screws. Ensure that the screws are clean and dry with
no lubrication applied.
10. Tighten the ten M10 x 110 flange head screws in three steps to the specified torque in the sequence shown.
7 3 1 5 9
8 4 2 6 10
55614

First 20 177
M10 x 110 flange head screw (10) Second 40 29.5
90-8M0082471 JULY 2014 Page 4A-35

11. Tighten the ten M8 x 50 perimeter screws to the specified torque in the sequence shown after the ten M10 screws are fully
tightened.
7 3 1 5
9
10 55615
8 4 2 6

M8 x 50 perimeter screws 35 25.8
12. Loosen the screws in the reverse order.
13. Remove the crankcase cover and measure the Plastigauge width. If the compressed Plastigauge measurement is not
within the listed specification, check the crankshaft code and measurement, cylinder block main bearing code, and the
bearing code selection.
48498
Main Bearing
Oil clearance 0.0500.084 mm (0.00190.0033 in.)
14. If the measurement is within specification, remove the Plastigauge material from the bearing and crankshaft surface.
15. Remove the crankshaft from the cylinder block. Lubricate the main bearings and thrust bearing with engine assembly
lubricant. Engine assembly lubricate can be purchased locally.
16. Place the crankshaft into the cylinder block.
Page 4A-36 90-8M0082471 JULY 2014

17. Install the crankshaft retainer onto the center main crankshaft bearing. Tighten the crankshaft retainer screws securely.
a b a - Crankshaft retainer
b - Crankshaft retainer screws
56207

guides
18. Assemble the piston/connecting rod assemblies. Refer to Piston/Connecting Rod Assembly.
19. Select the connecting rod bearings and install them into the connecting rods. Refer to Connecting Rod Bearing Grade
Selection.
20. Install the piston/connecting rod assemblies. Refer to Piston/Connecting Rod Assembly Installation.
21. Remove the crankshaft retainer from the cylinder block.
22. Apply a continuous 2 mm bead of Three Bond 1217F to the crankcase cover seal area as shown.
a - 2 mm bead of Three Bond 1217F

b b - Dowel pins (2)
b
55621

135 Three Bond 1217F Crankcase cover seal area 92-858005K02
23. Install the crankcase cover and the ten main bearing M10 x 110 flange head screws.
90-8M0082471 JULY 2014 Page 4A-37

24. Tighten the screws in three steps to the specified torque in the sequence shown.
7 3 1 5 9
8 4 2 6 10
55614

First 20 177
M10 x 110 flange head screw (10) Second 40 29.5
25. Install the ten perimeter M8 flange head screws.
26. Tighten the ten M8 x 50 perimeter screws to the specified torque in the sequence shown after the ten M10 x 110 screws
are fully tightened.
7 3 1 5
9
10 55615
8 4 2 6

M8 x 50 perimeter screws 35 25.8
Piston/Connecting Rod Assembly

1. Install the connecting rod into the piston with the connecting rod part number facing down and the dot on the piston dome
facing up.
2. Lubricate the piston pin with Lubriplate SPO 255.
3. Assemble the piston, connecting rod, piston pin, and secure with new piston pin retaining clips.
Page 4A-38 90-8M0082471 JULY 2014

IMPORTANT: The opening of the piston pin retaining clip should face towards the crown of the piston.
d a- Connecting rod (part number facing down)

b- Piston (dot on the piston dome facing up)
c
c- Piston pin
d- Piston pin retaining clip (2)
b
47994

136 Lubriplate SPO 255 Piston pin Obtain Locally
Piston Ring Installation

IMPORTANT: Always install new piston rings when rebuilding the engine. Use caution when installing piston rings to avoid
scratching the piston.
1. Apply Synthetic Blend 4Stroke Outboard Oil 25W40 to the piston ring grooves.
NOTE: For reference demarcation, the dot on the piston is at the 12 o'clock position and points towards the flywheel.

Synthetic Blend 4-Stroke
139 Piston ring grooves 92-8M0078629
Outboard Oil 25W-40
2. Install the oil ring expander onto the lower ring groove of the piston. Verify that the ring gap is at the 12 o'clock position.
IMPORTANT: The oil ring spacer cannot be rotated after the bottom and top oil control rings are installed.
3. Install the bottom oil control ring. Verify that the ring gap is at the 1:30 o'clock position.
4. Install the top oil control ring. Verify that the ring gap is at the 9:50 o'clock position.
5. Install the second compression ring with the dot side up. Verify that the ring gap is at the 7:30 o'clock position.
90-8M0082471 JULY 2014 Page 4A-39

6. Install the top compression ring with the dot side up. Verify that the ring gap is at the 1:30 o'clock position.
a
b
e d
c
2T
c
b
a f
e g
i
d
h
j 55632
a- Top oil control ring

b- Oil ring expander
c- Bottom oil control ring
d- Top compression ring
e- Second compression ring
f- Oil ring expander (ring gap is at the 12 o'clock position)
g- Bottom oil control ring gap (ring gap is at the 1:30 o'clock position)
h- Top oil control ring gap (locating pin)
i- Top compression ring gap (ring gap is at the 1:30 o'clock position)
j- Second compression ring gap (ring gap is at the 7:30 o'clock position)
Connecting Rod Bearing Grade Selection

Connecting Rod
Bearing oil clearance 0.0310.059 mm (0.00120.0023 in.)
Page 4A-40 90-8M0082471 JULY 2014

1. Verify the crankshaft journal code on the cylinder number one top counterweight.

a
55613
2. Verify the journal code on the connecting rod cap.
a - Stamped connecting rod crankshaft journal code "I"

b - Stamped connecting rod crankshaft journal code "0"
a b
0
47985
Connecting Rod Journal Code

47.00047.008 mm
Journal code "I"
(1.85041.8507 in.)
47.00847.016 mm
Journal code "0"
(1.85071.8510 in.)
3. Refer to the following bearing selection chart to select the correct crankshaft connecting rod bearings.
IMPORTANT: After selecting the correct bearing, install the bearing halves in the connecting rod and the matching
connecting rod cap to avoid mixing bearing sizes.
Connecting Rod Journal Code Crankshaft Journal Code Bearing Color Selection
I C Blue
I D White
0 C White
0 D Orange
4. Ensure that the connecting rod bearing area is clear of debris and contamination.
5. Install the locating tab of the upper half of the bearing into the slot on the connecting rod, and the locating tab of the lower
half of the bearing into the slot on the connecting rod cap. Carefully push the bearing onto the connecting rod and
connecting rod cap.
a - Connecting rod
b - Connecting rod locating tab
b
a
4389
90-8M0082471 JULY 2014 Page 4A-41

Piston Connecting Rod Assembly Installation

1. Lubricate the piston and rings with Synthetic Blend 4Stroke Outboard Oil 25W40.

139 Piston and rings 92-8M0078629
Outboard Oil 25W-40
2. Verify the location of the ring gaps.
Ring Gap Location

Top ring 1:30 o'clock position
Second ring 7:30 o'clock position
Top oil control ring Locating pin
Oil ring expander 12 o'clock position
Bottom oil control ring 1:30 o'clock position
3. Install the ring compressor from the connecting rod end. Ensure that the taper side of the ring compressor engages the
piston first. The ring compressor should be purchased locally.
a - Taper side of the ring compressor
48470
a
4. Carefully push the ring compressor onto the piston until the piston is even with the ring compressor.
NOTE: Do not force the ring compressor onto the piston. If the ring compressor installation is difficult, the top oil control
ring end gap may not be aligned with the locating pin on the piston.
48472
5. Lubricate the cylinder bore with a generous amount of Synthetic Blend 4Stroke Outboard Oil 25W40.

139 Cylinder bore 92-8M0078629
Outboard Oil 25W-40
6. Install the guide rods into the connecting rod threaded holes.

guides
Page 4A-42 90-8M0082471 JULY 2014

7. Install the piston into the cylinder bore with the piston demarcation towards the flywheel side of the engine.
8. Ensure that the ring compressor circumference rests completely on the cylinder block deck.
9. Secure the ring compressor to the cylinder block deck and push the piston into the cylinder bore.
NOTE: Do not force the piston assembly into the cylinder bore by striking it with a wood handle or other tool handle.
a a - Piston demarcation towards the flywheel

b - Ring compressor circumference completely on the cylinder
block deck
b
48473
10. Verify that the connecting rod is properly aligned with the crankshaft and push the connecting rod onto the crankshaft.
11. Install a piece of Plastigauge parallel to the crankshaft on the connecting rod crankshaft journal.
56213
12. Lubricate the rod cap screw threads and under the screw head with Lubriplate SPO 255.

13. Install the rod cap and screws. Verify the rod cap alignment and tighten the screws in three stages to the specified torque.
IMPORTANT: Do not allow the crankshaft to rotate while checking the bearing clearance with Plastigauge.
a - Rod cap screws
56215

First 10 88.5
90-8M0082471 JULY 2014 Page 4A-43

14. Remove the rod cap and measure the Plastigauge width. If the compressed Plastigauge measurement is not within the
listed specification, check the crankshaft measurement, connecting rod measurement, and the bearing grade selection.
56216
Connecting Rod
Bearing oil clearance 0.0310.059 mm (0.00120.0023 in.)
15. If the clearance is within the listed specifications, carefully remove the Plastigauge material from the bearing and
crankshaft surface.
16. Push the connecting rod away from the crankshaft and apply engine assembly lubricant to the bearing and journal. Engine
assembly lubricant can be purchased locally.
17. Pull the connecting rod onto the crankshaft journal.
18. Lubricate the rod cap screw threads and under the screw head with Lubriplate SPO 255.

19. Install the rod cap and screws. Verify the rod cap alignment and tighten the screws in three stages to the specified torque.

First 10 88.5
20. Install the remaining connecting rod assemblies, checking the bearing clearance before applying the lubrication for the final
assembly process.
Crankshaft Seal Installation

1. Clean the crankshaft seal bore with a mild solvent and allow to dry.
2. Insert the spacer into the seal bore.
48586
Page 4A-44 90-8M0082471 JULY 2014

3. Lubricate the crankshaft seal lip with Extreme Grease and install the seal onto the crankshaft.
48587

Extreme Grease Crankshaft seal lip 8M0071842
4. Use an appropriate driver tool to install the crankshaft seal.
5. Install the flywheel washer and screw. Tighten the screw to the specified torque.
a b a- Screw
b- Washer
c c- Driver
d- Seal
48589

Screw 27 20
6. Remove the tool and install the retaining ring.
48590
90-8M0082471 JULY 2014 Page 4A-45

Seal Installation for a Worn Crankshaft Seal Area

When a seal groove has worn into the crankshaft, press the seal into the cylinder block and then install the spacer. Retain the
spacer and seal with the retaining ring.
a a - Retaining ring
b - Spacer
b c - Seal
48591
Cylinder Head Installation

IMPORTANT: It is expected that the valve clearance will change to a value that minimizes the amount of additional adjustment
after the cylinder head is installed and tightened to the specified torque.
1. Install the flywheel and secure it with the washer and bolt. Do not tighten the bolt.
2. Align the flywheel timing mark with the aft starter mounting boss on the cylinder block.
IMPORTANT: Aligning the flywheel timing mark with the aft starter mounting boss allows for sufficient valve clearance to
rotate the camshaft when the cylinder head is secured to the cylinder block.
a - Aft starter mounting boss

b - Flywheel timing mark
b
a
56281
3. Verify that the dowel pins are installed on the cylinder block.
4. Verify that the camshaft is positioned so the pin on the camshaft is at 9 o'clock.
Page 4A-46 90-8M0082471 JULY 2014

IMPORTANT: To avoid damage from the valves hitting the pistons, ensure that the camshaft is not rotated from this
position until after the timing chain is installed.
48298
5. Install the cylinder head gasket.

6. Install the cylinder head and secure it with ten M10 x 110 flange head screws.
7. Tighten the screws in three stages to the specified torque in the sequence shown.
7 3 1 5
9
8 4 2 6 10 56221

First 20 14.7
M10 x 110 flange head screws (10) Second 35 25.8
Final Turn addtional 60
90-8M0082471 JULY 2014 Page 4A-47

8. Install three M6 x 40 screws and tighten them to the specified torque in the sequence shown.
2
1
56223

M6 x 40 screws 10 88.5
9. Install the timing chain guide and timing chain blade. Secure the guide and the blade to the cylinder block with M8 x 30
shoulder screws. Apply Synthetic Blend 4Stroke Outboard Oil 25W40 to the flange head of the shoulder screw. Apply
Loctite 242 Threadlocker to the screw threads. Tighten the screws to the specified torque.
10. Install the crankshaft Oring and lubricate with 24C with PTFE.
a- Timing chain blade

b- M8 x 30 shoulder screws
b c- Timing chain guide
d- Crankshaft oring
a d c
56224

M8 x 30 shoulder screws 24 17.7

139 Flange head of shoulder screw 92-8M0078629
Outboard Oil 25W-40
66 Loctite 242 Threadlocker Tensioner guide screw threads 92-809821
95 2-4-C with PTFE Crankshaft O-ring 92-802859A 1

11. Align the timing mark on the flywheel with the timing mark on the top of the cylinder block.
Page 4A-48 90-8M0082471 JULY 2014

IMPORTANT: To avoid damage from the valves hitting the pistons, ensure that the crankshaft is not rotated from this
position during assembly.
a - Timing mark on the top of the cylinder block

b - Timing mark on the flywheel
56218
12. Locate the timing chain links that are marked with yellow paint. The link with the line is for the crankshaft timing mark and
the link that is yellow is for the camshaft timing mark.
IMPORTANT: If the yellow paint on the timing chain links cannot be identified, a new timing chain should be installed.
a b a - Camshaft link timing mark

b - Crankshaft link timing mark
48545
13. Install the timing chain link with the yellow line onto the crankshaft. Verify that the link with the line is aligned with the timing
mark on the crankshaft.
a a - Yellow line on timing chain link

b - Crankshaft timing chain alignment mark
56230
90-8M0082471 JULY 2014 Page 4A-49

14. Install the camshaft gear onto the timing chain, aligning the yellow link with the triangle on the gear and install the camshaft
gear onto the camshaft.
a - Yellow link
b c b - Camshaft gear timing mark
c - Camshaft pin
48551
15. Lubricate the special lefthand thread camshaft gear screw threads and flange head with Synthetic Blend 4Stroke
Outboard Oil 25W40 and retain the camshaft gear with the camshaft gear screw.

4-Stroke 10W-30
110 Camshaft gear screw threads and flange head 92-858045K01
Outboard Oil
16. Secure the camshaft and tighten the screw in two stages to the specified torque.
17. After the first torque is completed, mark the camshaft gear at the first line on the camshaft gear screw. Rotate the screw to
align with the 20 mark on the camshaft gear.
a - Camshaft gear first

b torque location 45 Nm
(33.2 lbft)
c b - Camshaft gear mark
c - 20 mark on the
camshaft gear screw
a
48552

First 45 32.2
Camshaft gear screw (lefthand thread)
18. Apply Lubriplate SPO 255 to the timing chain tensioner assembly and insert into the cylinder head.

136 Lubriplate SPO 255 Timing chain tensioner assembly Obtain Locally
Page 4A-50 90-8M0082471 JULY 2014

19. Install an Oring onto the timing chain tensioner cover and secure with a bracket and two M6 x 25 flange head screws.
Tighten the screws to the specified torque.
55002

Screws (M6 x 25) (2) 10 88.5
20. Check the lash on all the valves and correct if necessary. Refer to Section 4B Adjusting Valve Clearance.
IMPORTANT: The clearance specifications apply when the ball stud locknut is tightened to the specified torque.
IMPORTANT: When measuring clearance with a feeler gauge blade, you must change sizes until you feel a firm drag
when pushing and pulling on the gauge. Verify your results by trying the next size larger blade. It must be much more
difficult or nearly impossible to enter the gap. Then try the next size smaller blade. It must have little or no drag. If your
results are different, your technique is incorrect. Common mistakes are failing to hold the blade perpendicular to the gap or
twisting and flexing the blade.
Camshaft to Roller Clearance Specifications

Intake valve 0.075 mm 0.025 mm (0.003 in. 0.001 in.)
Exhaust valve 0.150 mm 0.025 mm (0.006 in. 0.001 in.)

Ball stud locknut 20 177
21. Install a new cam cover seal and install the cam cover.
90-8M0082471 JULY 2014 Page 4A-51

22. Secure the cover with 13 M6 x 25 screws. Tighten the screws to the specified torque, starting in the center and working
outwards.
54981

M6 x 25 screws (13) 10 88.5
Oil Pump Installation

1. Verify that the crankshaft is at #1 TDC (top dead center) using the timing marks on the crankshaft and the bottom of the
cylinder block.
a - Timing mark on crankshaft

a b - Timing mark on the bottom of the cylinder block
55667
Page 4A-52 90-8M0082471 JULY 2014

2. Pour approximately 30 cc (1.0 oz) of engine oil into the oil pump and rotate the oil pump drive gerotor to distribute the oil.
a - Oil pump drive gerotor

b - Pour approximately 30 cc (1.0 oz) of engine oil
into the oil pump
a
55663
3. Align the oil pump drive gerotor as shown in the following illustration.
55664
4. Lubricate the oil pump seal lip and the oil pump gerotor drive flats with Extreme Grease.

Extreme Grease Oil pump seal lip and oil pump gerotor drive flats 8M0071842
5. Install the oil pump assembly onto the cylinder block and secure it with four M6 hex flange screws.
6. Verify the oil pump is correctly seated on the cylinder block and tighten the screws to the specified torque in the sequence
shown.
3 2
55666
90-8M0082471 JULY 2014 Page 4A-53


M6 hex flange screws (4) 10 88.5
Installing Powerhead Components

Installing Powerhead Components as an Assembly
Stator Installation
1. Install the stator as shown and place it onto the mounting bosses on the crankcase.
IMPORTANT: The stator must be oriented as shown to connect the stator harness to the engine harness connector.
2. Apply Loctite 242 Threadlocker to the stator mounting screws. Install the stator mounting screws and tighten them to the
specified torque in a crossing pattern.
a - M6 x 25 screws (6)
55019

Stator mounting screws (M6 x 30) (6) 10 88.5

66 Loctite 242 Threadlocker Stator mounting screws 92-809821
Flywheel Installation
1. Install the flywheel key into the crankshaft.
2. Align the flywheel with the flywheel key and install the flywheel onto the crankshaft.
b a a - Crankshaft
b - Flywheel key
54994
Page 4A-54 90-8M0082471 JULY 2014

3. Secure the flywheel with the flywheel screw and washer. Use the flywheel holding tool to hold the flywheel and tighten the
flywheel screw to the specified torque in two stages.
a b
d
54999
a- Flywheel screw
b- Washer
c- Torque wrench with M30 socket
d- Flywheel holding tool

First 100 73.8
Flywheel screw (M20 x 168)
Final 190 140
Starter Motor, Shift Bracket, Intake Manifold, Thermostat Housing, and Sensors
1. Replace the Oring on the block water temperature sensor, oil pressure sensor, and the water pressure sensor (if
equipped).
13384
Water temperature sensor shown
2. Apply Loctite 567 PST Pipe Sealant to the threads of the block water temperature sensor and install it into the cylinder
block. Tighten the block water temperature sensor to the specified torque.
3. Apply Loctite 567 PST Pipe Sealant to the threads of the oil pressure sensor and install it into the cylinder block. Tighten
the oil pressure sensor to the specified torque.
4. Apply Loctite 567 PST Pipe Sealant to the threads of the water pump indicator hose fitting and install it onto the cylinder
head. Tighten the fitting securely and orient it as shown.
5. Apply Loctite 567 PST Pipe Sealant to the threads of the optional water pressure sensor and install it into the cylinder
head, if required. Tighten the water pressure sensor to the specified torque.
90-8M0082471 JULY 2014 Page 4A-55

6. Install the crankshaft position sensor and secure it with two M5 x 13 screws. Tighten the screws to the specified torque.
a- Screws securing the crankshaft position sensor

b- Water pressure sensor (optional)
a c- Water temperature sensor
e- Water pump indicator hose fitting
b
e c
d 54976

Water pump indicator hose plastic fitting threads, block
9 water temperature sensor threads, oil pressure sensor 92-809822
Sealant
threads

Block water temperature sensor 15 132.7
Water pressure sensor (optional) 15 132.7
Crankshaft position sensor screws 5 44.2
Oil pressure sensor 15 132.7
7. Install a new Oring onto the thermostat housing.
8. Secure the thermostat housing to the cylinder block with two M6 x 25 screws. Tighten the screws to the specified torque.
9. Install the thermostat dump hose and secure it with a 36.1 mm metal hose clamp
10. Install the water pump indicator hose onto the plastic fitting and secure the hose with a cable tie.
c d a- Water pump indicator hose

b- 36.1 mm metal hose clamp
b e
d c- Cable tie
d- Water pump indicator hose fitting
a
e- Thermostat housing screws (2)
f- Thermostat dump hose
f
54973

Thermostat housing screws (M6 x 25) screws 10 88.5
11. Install the crankcase ventilation hose onto the cam cover if it was removed. Secure the hose to the cover with a 25.6 mm
metal hose clamp.
12. Secure the thermostat dump hose and water pump indicator hose to the retainers on the cam cover.
Page 4A-56 90-8M0082471 JULY 2014

13. Verify that the intake manifold seals are installed.
55200
14. Install the intake manifold onto the cylinder head and secure it with ten M6 x 37 flange head screws. Tighten the screws to
the specified torque in the sequence shown.
9
6
3
2 1
10
5
4
8 55207

Intake manifold screws (M6 x 37 flange head) (10) 10 88.5
15. Install the three screws securing the throttle/shift cable bracket to the cylinder block. Tighten the screws to the specified
torque.

Screws securing the throttle/shift cable bracket to the cylinder block 11 97.4
16. Apply Loctite 242 to the throttle cam screw threads. Install the screw securing the throttle cam to the cylinder block. Tighten
the screw to the specified torque.

Screw securing the throttle cam to the cylinder block 10 88.5

66 Loctite 242 Threadlocker Throttle cam screw threads 92-809821
90-8M0082471 JULY 2014 Page 4A-57

17. Install the two screws securing the drip tray to the cylinder block. Tighten the screws to the specified torque.
a - Screw securing the throttle cam to the cylinder block

b - Screws securing the drip tray to the cylinder block
c - Screws securing the throttle/shift bracket to the cylinder
block
a b
54966

Screw securing the drip tray to the cylinder block 10 88.5
18. Install the three M8 x 80 screws and washers securing the starter motor assembly to the cylinder block. Tighten the screws
to the specified torque.
19. Secure the starter motor ground cable to the cylinder block with the M6 x 13 screw. Tighten the screw to the specified
torque and cover the screw and cable end with Liquid Neoprene.
a - M8 x 80 screws and washers (3)

b - Starter motor ground cable screw
54964

Starter motor screws (M8 x 80) (3) 24 17.7
Starter motor ground cable screw (M6 x 16) 10 88.5

25 Liquid Neoprene Starter motor ground cable screw and cable end 92- 25711 3
Page 4A-58 90-8M0082471 JULY 2014

Wire Harness and Engine Control Module (ECM) Installation

1. Install the three M6 x 25 screws, washers, and grommets that secure the ECM to the cylinder block. Install the Jclip as
shown. Tighten the screws to the specified torque.
a - M6 x 25 screws (3) with washers and grommets

b b - Jclip
54937

M6 x 25 screws (3) 10 88.5
2. Install the electrical plate and harness assembly onto the cylinder block and secure it with three screws and washers.
Tighten the screws to the specified torque.

M6 x 25 screws (3) 10 88.5
3. Connect the ECM harness connector the ECM and secure it to the ECM with the latch on the connector.
4. Connect the starter solenoid activation lead (yellow with red tracer) to the starter solenoid. Tighten the screw and cover the
connection with Liquid Neoprene.
a - M6 x 25 screws and washers (3)

b - Starter solenoid activation lead (yellow/red)
c - ECM harness connector
b
a
54936

M6 x 25 screws (3) 10 88.5
90-8M0082471 JULY 2014 Page 4A-59


25 Liquid Neoprene Starter solenoid activation lead connection 92- 25711 3
Powerhead Installation onto the Midsection

1. Install the flywheel puller/lifting ring and secure it with the screws. Tighten the three screws to the specified torque.
54915

Flywheel puller/lifting ring screws 27 20
! CAUTION
Improper lifting during removal or installation of the engine can cause injury or damage to engine components. Use a hoist,
lifting arm, or other approved lifting device. Do not allow the lifting device to hook or compress any engine components.
2. Suspend the powerhead to access the oil pump.
3. Install a 34.6 mm metal hose clamp onto the oil pickup tube. Install the oil pickup tube onto the oil pump. Use the hose
clamp tool to secure the pickup tube to the oil pump. The clamp must cover the white mark on the oil pickup tube, and the
crimped side of the metal hose clamp must face towards the crankshaft.
a - 34.6 mm metal hose clamp
48074

4. Install the powerhead gasket onto the adapter plate.
5. Ensure that the gearcase is in neutral, and that the shift shaft bellcrank position is towards the starboard end of the tilt tube.
Page 4A-60 90-8M0082471 JULY 2014

6. Verify that the shift slide roller is in the neutral position (aligned with the casting mark on the shift bracket).
a - Shift shaft bellcrank position towards the starboard end of the tilt
a tube
b - Shift slide roller
c - Casting mark on the shift bracket
b
c 55840
7. Carefully lower the powerhead onto the midsection. Install the engine oil dipstick to prevent debris from entering the sump.
8. Install the shift link onto the shift shaft and secure it with a washer and nut. Tighten the nut to the specified torque.
a a - Nut
b - Washer
c b c - Shift link
54903

Nut 6 53.1
9. Install three M10 x 60 screws on the port side of the midsection. Do not tighten the screws.
54912
90-8M0082471 JULY 2014 Page 4A-61

10. Install four M10 x 60 screws on the starboard side of the midsection. Do not tighten the screws.
54914
11. Install four M8 x 40 screws at the back of the midsection. Do not tighten the screws.
48057
Page 4A-62 90-8M0082471 JULY 2014

12. Tighten the powerhead mounting screws to the specified torque in the sequence shown.
6 4 3
5
1
11
2
7 8 9 10 55127
View looking at the powerhead from below

Powerhead mounting screws 16 and 11 (M10 x 60) 60 44
Powerhead mounting screws 710 (M8 x 40) 27 20
13. Lubricate the two exhaust manifold joints with a mild liquid detergent.
55134
14. Lubricate the Orings on the exhaust tube with a mild liquid detergent.
15. Install the exhaust manifold gasket onto the cylinder head locating pins. Ensure that the gasket surface is free of oil and
contaminants.
16. Install the exhaust manifold onto the exhaust tube and push down on the exhaust manifold.
17. Rotate the exhaust manifold onto the cylinder head, aligning the pins on the head with the holes in the exhaust manifold.
90-8M0082471 JULY 2014 Page 4A-63

18. Secure the exhaust manifold with six M8 x 35 flange head screws. Starting at the center of the manifold and working
outwards, tighten the screws to the specified torque.
a a a - Exhaust manifold screw (6)

b - Voltage regulator
a
b
54909

Exhaust manifold screws (M8 x 60) (6) 28 20.6
19. Install the spark plugs and tighten them to the specified torque.

Spark plugs 27 20
20. Install the spark plug wire retainer onto the exhaust manifold with two push pins.
21. Install the spark plug wires into the spark plug wire retainers and onto the spark plugs.
22. Attach the cooling water hose to the fitting behind the exhaust manifold. Secure the hose with a cable tie.
23. Install a new voltage regulator gasket onto the exhaust manifold. Tighten the six M6 x 30 screws securing the voltage
regulator to the exhaust manifold to the specified torque.
a- Spark plug wires

b- Spark plug wire retainer on the cam cover
c- Fitting behind the exhaust manifold
a
d- Spark plug wire retainer on the cam cover
e- Exhaust manifold
f- Voltage regulator
a
f
e a
c
d a
54906
Page 4A-64 90-8M0082471 JULY 2014


Voltage regulator screws (M6 x 30) (6) 10 88.5
24. Connect the fuel supply hose connector to the fuel filter outlet port.
a - Fuel supply hose connector at the fuel filter outlet port

b - Fuel filter
a b
54905
25. Install the water pump indicator hose onto the fitting on the adapter plate. Secure the hose with a cable tie.
26. Install a new Oring onto the water dump hose fitting. Install the water dump hose fitting to the adapter plate. Tighten the
M6 x 25 screw to the specified torque.
a - Cable tie securing the water pump indicator hose

b b - Water dump hose fitting
c - M6 x 25 screw
54900

Water dump hose fitting screw (M6 x 25) 10 88.5
27. Install the manifold pressure reference line onto the fitting on the fuel supply module (FSM).
54899
28. Install a 16.2 mm metal hose clamp onto the highpressure fuel hose. Install the highpressure fuel hose onto the fuel rail.
90-8M0082471 JULY 2014 Page 4A-65

IMPORTANT: Ensure that the fuel strainer is installed into the end of the highpressure fuel hose.
a - Highpressure fuel hose

c - Fuel rail
a
b
c
54898
29. Connect the fuel pump connector to the engine harness connector. Secure the connector to the fuel rail with a cable tie.
a - Fuel rail
b - Fuel pump connector
c - Cable tie
a
b
c
54897
30. Lubricate the exhaust tube grommet and alignment pin grommet with a mild liquid detergent. Guide the exhaust tube and
alignment pin on the idle exhaust muffler into the grommets on the adapter plate and press down to install.

b - Adapter plate
b
54893
31. Refill the engine oil. Refer to Section 1B Changing Engine Oil.
32. Install the flywheel cover by pressing it down onto its grommet seats.
33. Install the throttle and shift cables, fuel line, and remote control harness.
34. Install the upper and lower cowls. Refer to Section 5A Lower Cowl Installation.
! CAUTION
Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage
the electrical system. Always disconnect the negative () battery cable first and connect it last.
35. Starting with the positive lead, connect the battery cables to the battery terminals.
Engine Breakin Procedure

IMPORTANT: Failure to follow the engine breakin procedures can result in poor performance throughout the life of the engine
and can cause engine damage. Always follow breakin procedures.
Page 4A-66 90-8M0082471 JULY 2014

1. For the first two hours of operation, run the engine at varied throttle settings up to 4500 RPM or at threequarter throttle,
and at full throttle for approximately one minute every ten minutes.
2. For the next eight hours of operation, avoid continuous operation at full throttle for more than five minutes at a time.
90-8M0082471 JULY 2014 Page 4A-67

Notes:
Page 4A-68 90-8M0082471 JULY 2014

Cylinder Head
Powerhead
Section 4B - Cylinder Head
Table of Contents
Cylinder Head.................................................................... 4B-4 Valve Springs............................................................4B-13
Cylinder Head Components...............................................4B-6 Cylinder Head........................................................... 4B-14
Cylinder Head Specifications............................................. 4B-2 Valve Guides............................................................ 4B-15
Cylinder Head Service Recommendations........................ 4B-8 Valve Seat Reconditioning........................................4B-16
Cylinder Head Disassembly...............................................4B-8 Cylinder Head Assembly..................................................4B-17
Camshaft Removal..................................................... 4B-8
Cylinder Head Galley Plug Removal........................ 4B-10
Cylinder Head Galley Plug Installation..................... 4B-17
Valve Installation.......................................................4B-18 4
Cleaning, Inspection, and Repair.....................................4B-11
Camshaft.................................................................. 4B-11
Camshaft Installation................................................ 4B-19
Adjusting Valve Clearance........................................4B-21 B
Valve Specifications..................................................4B-12
90-8M0082471 JULY 2014 Page 4B-1

Cylinder Head

Maximum warp (for cylinder head) 0.1 mm (0.0039 in.)
0.05 mm (0.0019 in.)
directions
Deck
0.025 mm (0.0009 in.)
directions
Minimum datum height (combustion chamber) 4.8 mm (0.1889 in.)
Number of valves 8
Number of valves per cylinder 2
29.00029.021 mm
Camshaft bearing inside diameter (cylinder head)
(1.14181.1425 in.)
19.975 0.025 mm
Cylinder head camshaft center bearing thrust face
(0.7864 0.0009 in.)
28.97 0.01 mm
Camshaft bearing journal
(1.1405 0.0004 in.)
Camshaft lobe height (115 HP Intake 47.2046 mm (1.8584 in.)

and 80 Jet) Exhaust 47.555 mm (1.8722 in.)
Intake 45.1377 mm (1.777 in.)
Camshaft lobe height (7590 HP)
Exhaust 47.0666 mm (1.853 in.)
0.075 0.025 mm
Intake
Camshaft to roller clearance (0.003 0.001 in.)
(lash) (cold) 0.150 0.025 mm
Exhaust
(0.006 0.001 in.)
Valve seat angles (referenced Intake 30, 44 0.25, 60

from the valve axis) Exhaust 25, 39 0.25, 53, 67
1.00 0.1 mm
Intake (44)
Valve seat width (0.0394 0.0039 in.)
Exhaust (39) 1.50 0.1 mm (0.059 0.004 in.)
Uncompressed 54.62 mm (2.150 in.)
240 12 N (53.95 2.70 lbf)
Valve spring height spring pressure
760 34 N (170.85 7.64 lbf)
spring pressure
Intake 45.2 0.1 mm (1.780 0.004 in.)
Valve outside diameter
Exhaust 35 0.1 mm (1.378 0.004 in.)
Intake 45
Valve face angle
Exhaust 40
0.875 0.2 mm
Intake
(0.0345 0.0078 in.)
Valve margin width
1.45 0.2 mm
Exhaust
(0.0571 0.0078 in.)
6.97 0.008 mm
Intake
(0.2744 0.0003 in.)
Valve stem diameter
6.96 0.008 mm
Exhaust
(0.2740 0.0003 in.)
Valve stem runout (service limit
Intake and exhaust 0.03 mm (0.0012 in.)
measured at valve face)
Page 4B-2 90-8M0082471 JULY 2014

Cylinder Head

121.96 0.25 mm
Intake
(4.8016 0.01 in.)
Valve height
122.44 0.25 mm
Exhaust
(4.8204 0.01 in.)
7.0017.021 mm
Valve guide bore inside diameter Intake and exhaust
(0.27570.2764 in.)
0.0230.059 mm
Intake
Valve stem to valve guide (0.00090.0023 in.)
clearance 0.0330.069 mm
Exhaust
(0.00120.0027 in.)
15.1 0.25 mm
Valve guide height Intake and exhaust
(0.595 0.0098 in.)

95 2-4-C with PTFE Installing valve spring retainer locks 92-802859A 1
Galley plug threads
Synthetic Blend 4-Stroke Valve guide seal
139 92-8M0078629
Outboard Oil 25W-40 Ball stud assembly threads
Rocker arm roller bearing
Special Tools
Valve Spring Compressor 91809494A 1
Removes and installs valve springs.
3454
90-8M0082471 JULY 2014 Page 4B-3

Cylinder Head
Cylinder Head
10
1
9 2
6 5
55130
Page 4B-4 90-8M0082471 JULY 2014

Cylinder Head
Cylinder Head
Torque
Cylinder head assembly (65 Jet, 75, 80, 90, 100 HP)
1 1
Cylinder head assembly (80 Jet and 115 HP)
2 1 Oil fill cap
3 1 Oring
4 13 Screw (M6 x 25), stainless steel 10 88.5
5 1 Cam cover assembly
6 1 Cam cover seal
7 1 Wire clip
First 20 177
9 10 Screw (M10 x 95) Second 35 25.8
Final Turn additional 60
10 1 Cylinder head gasket
90-8M0082471 JULY 2014 Page 4B-5

Cylinder Head
Cylinder Head Components

11
2
19
12
1
4
16 17
14 15 31 13 10
18 8
9
3
19
5
20
21
30
25 24
22 29
23 27 28
24 26 55131
Page 4B-6 90-8M0082471 JULY 2014

Cylinder Head
Cylinder Head Components

Torque
Cylinder head assembly (65 Jet, 75, 80, 90, 100 HP)
1 1
Cylinder head assembly (80 Jet, 115 HP)
2 4 Exhaust valve seat
3 4 Intake valve seat
4 8 Valve guide
5 1 Plug (30 mm) and Oring 55 40.5
8 5 Camshaft cap (not sold separately)
First 6 53
9 10 Screw
Final 12 106
10 8 Roller finger follower
11 4 Exhuast valve
12 4 Intake valve
13 8 Ball stud
14 8 Valve retainer
15 16 Key
16 8 Valve stem seal
17 8 Valve spring
Camshaft (65 Jet, 75, 80, 90, 100 HP)
18 1
Camshaft (80 Jet, 115 HP)
19 2 Dowel pin
20 2 Dowel pin
21 1 Chain blade
22 1 Chain guide
23 1 Sprocket
24 2 Shoulder screw (M8 x 1.25) 24 17.7
25 1 Cam drive chain
First 45 33.2
26 1 Screw (M12 x 40) lefthand thread
Final additional 20
27 1 Plug (M10 x 1.5)
28 1 Oring
29 1 Cam tensioner end cap
31 8 Hex nut 20 177
90-8M0082471 JULY 2014 Page 4B-7

Cylinder Head
Cylinder Head Service Recommendations

All engines, from a single cylinder low horsepower to a multicylinder highperformance racing engine, require frequent
maintenance and inspection schedules because of the extreme duty cycles and related stress these products endure. Failure to
follow the maintenance and service schedule could lead to catastrophic engine failure and increased owner expense.
The cylinder head is the most important component of the engine. It has extremely close tolerance machined components that
must be repaired by an accomplished Master Technician with experience servicing highperformance engines. A skilled
machine shop that is familiar with automotive engine machining techniques, must be utilized when the cylinder head requires
any type of machining or clearance correction repair. Damage to the cylinder head combustion chamber area from a
component failure, debris, or improper machining, will alter the emissions output of the engine and may require the cylinder
head be replaced instead of repaired. Careful attention to details, proven repair techniques, and factory supplied high quality
parts are required to restore this engine to the original factory emissions and performance output.
IMPORTANT: The cylinder head is machined to extremely close tolerances and should not be modified by inexperienced
personnel. Cutting the valve seat without close attention to detail, can change the combustion chamber area where the engine
is not within the factory emissions specification and may affect the engine's performance.
Cylinder Head Disassembly

Camshaft Removal
NOTE: Refer to Section 4A Cylinder Block/Crankcase for the removal of the cylinder head from the cylinder block.
IMPORTANT: Follow the camshaft removal procedure exactly. Failure to follow the removal procedure of the camshaft caps
could result in damage to the camshaft, camshaft caps, and the cylinder head camshaft bearing area.
1. Place the cylinder head onto a support platform so the valves will not contact the workbench or support platform.
2. Use the hex on the camshaft to rotate the camshaft so the camshaft gear pin is located at the 9 o'clock position. This
allows the camshaft to have minimal valve spring tension when removing the camshaft caps.
a - Camshaft gear pin at 9 o'clock position
48298
3. Loosen all of the camshaft caps 1/4 turn, starting at the top number 1 camshaft cap, and working sequentially towards
camshaft cap number 5.
4. Remove camshaft caps 1, 4, and 5.
4 3 2 1
5
55853
5. Loosen the screws from camshaft cap 2 and 3, 1/4 turn each until the camshaft does not have any valve spring tension on
it.
Page 4B-8 90-8M0082471 JULY 2014

Cylinder Head
IMPORTANT: Rotating the camshaft cap screws more than 1/4 turn could cause damage to the camshaft, camshaft caps,
and the cylinder head camshaft bearing area.
a - Cap 3
b - Cap 2
a b
55854
6. Remove the camshaft caps and lift the camshaft off the cylinder head.
7. Remove the rocker arms.
IMPORTANT: Use care when removing the rocker arms to prevent damage to the retaining clips on the rocker arms.
55855
8. Loosen the ball stud nut and remove the ball stud.
a a - Ball stud
b - Ball stud nut
55856
90-8M0082471 JULY 2014 Page 4B-9

Cylinder Head
9. Compress the valve springs with the valve spring compressor tool and remove the valve spring retainer locks.
a a - Valve spring compressor tool

b - Valve spring retainer locks
48303

10. Remove the valve spring and retainer.
11. Push the valve out of the cylinder head.
12. Remove the valve seal with a pair of pliers.
48310
Cylinder Head Galley Plug Removal

1. Remove all of the oil and water galley plugs from the cylinder head.
NOTE: It may be necessary to lightly tap on the galley plugs with a brass drift and a hammer to break the galley plug seal.
Page 4B-10 90-8M0082471 JULY 2014

Cylinder Head
2. Remove the Orings from the galley plugs and discard the Orings.
a a a a - (10 mm) galley plug

b - (30 mm) galley plug
c - (24 mm) galley plug
a
a
55885
Cleaning, Inspection, and Repair

Camshaft
1. Carefully inspect the camshaft lobe surfaces for cracks, pits, scoring, or corrosion. If any of these conditions are found,
replace the camshaft.
2. Measure the camshaft lobe at its maximum valve lift location. Replace the camshaft if the dimensions are out of
specification.
21391
Camshaft Lobe (115 HP and 80 Jet)

Intake 47.2046 mm (1.8584 in.)
Exhaust 47.555 mm (1.8722 in.)
Camshaft Lobe (7590 HP)

Intake 45.1377 mm (1.777 in.)
Exhaust 47.0666 mm (1.853 in.)
NOTE: The 7590 HP camshaft has an identification groove between the number 3 and number 4 cylinder camshaft lobes.
90-8M0082471 JULY 2014 Page 4B-11

Cylinder Head
3. Measure all of the camshaft bearing journals. Replace the camshaft if the journal dimensions are out of specification.
21393
Camshaft Bearing
Journal diameter 28.97 0.01 mm (1.1405 0.0004 in.)
Valve Specifications
Intake Valve
IMPORTANT: If the intake valve does not measure to the following specifications, it must be replaced.
Intake Valve Specifications

121.96 0.25 mm
Height (a)
(4.8016 0.01 in.)
Valve stem diameter (b) 6.97 0.008 (0.2744 0.0003 in.)
Valve face angle (c) 45
Intake valve Outside diameter (d) 45.2 0.1 mm (1.780 0.004 in.)
0.875 0.2 mm
Valve margin width (e)
(0.0345 0.0078 in.)
Valve stem service limit runout (measured at valve
0.03 mm (0.0012 in.)
face)
e
a b
c
d 47971
Exhaust Valve
IMPORTANT: If the exhaust valve does not measure to the following specifications, it must be replaced.
Page 4B-12 90-8M0082471 JULY 2014

Cylinder Head
Exhaust Valve Specifications

122.44 0.25 mm
Height (a)
(4.8204 0.01 in.)
6.96 0.008 mm
Valve stem diameter (b)
(0.2740 0.0003 in.)
Valve face angle (c) 40
Exhaust valve
Outside diameter (d) 35 0.1 mm (1.378 0.004 in.)
1.45 0.2 mm
Valve margin width (e)
(0.0571 0.0078 in.)
Valve stem service limit runout (measured at valve
0.03 mm (0.0012 in.)
face)
e
a
b c
d 47969
Valve Springs
The engine is an interference valve train design. A weak valve spring could possibly cause extensive damage to the engine.
Check the height of each spring. Replace all of the valve springs if any spring is out of specification.
48325
Valve Spring
Height (uncompressed) 54.62 mm (2.150 in.)
90-8M0082471 JULY 2014 Page 4B-13

Cylinder Head
Compress each valve spring to the specified height. If the amount of spring force is not within the specified range, replace the
valve spring.
48846
Spring Force
Compressed to 47.08 mm (1.854 in.) 240 12 N (53.95 2.70 lbf)
Compressed to 33.91 mm (1.335 in.) 760 34 N (170.85 7.64 lbf)
Cylinder Head
1. Inspect the cylinder head for mineral deposits or corrosion in the water passageways. Clean any deposits or corrosion
observed.
2. Thoroughly flush the oil galley with a clean solvent.
NOTE: Use a bore brush to clean the oil galley of sludge and to dislodge any possible debris.
3. Inspect the cylinder head for carbon deposits in the combustion chamber. Use a round scraper to clean away deposits. Be
careful not to scratch or remove material.
NOTE: Use plastic media or baking soda to pressure blast (remove) deposits without damaging the combustion area.
4. Measure the cylinder head for any warp. Replace the cylinder head if it is out of specification.
NOTE: Use a straightedge and a feeler gauge to inspect the cylinder head for any indication of warp.
48320
Cylinder Head
Maximum deck warp (for cylinder head) 0.1 mm (0.0039 in.)
Maximum warp within 100 mm (3.937 in.) in all directions 0.05 mm (0.0019 in.)
Maximum warp within 25 mm (0.984 in.) in all directions 0.025 mm (0.0009 in.)
Page 4B-14 90-8M0082471 JULY 2014

Cylinder Head
5. Measure the cylinder head camshaft center bearing thrust face. Replace the cylinder head if out of specification.
a
a - Cylinder head camshaft center
bearing thrust face
48350
Cylinder Head
Camshaft thrust face 19.975 0.025 mm (0.7864 0.0009 in.)
6. Install the camshaft caps in their correct location. Tighten the camshaft cap screws to the specified torque.

Camshaft cap screw 12 106
7. Measure the inside dimension of the camshaft bearing journal. Replace the cylinder head if the dimension is out of
specification.
a - Camshaft bearing cap inside dimension
a
21395
Camshaft Bearing Journal

Inside diameter 29.00029.021 mm (1.14181.1425 in.)
8. Measure the combustion chamber height. Replace the cylinder head if the dimension is out of specification.
a - Combustion chamber height
49358
Combustion Chamber Specification

Combustion chamber height (minimum) 4.8 mm (0.1889 in.)
Valve Guides
1. Clean the valve guides with a solvent and valve guide brush to remove any varnish deposits.
90-8M0082471 JULY 2014 Page 4B-15

Cylinder Head
2. Measure the valve guide bore with a valve guide bore gauge. If the valve guide is out of specification, replace it.
a - Valve guide bore

a
20975
Valve Guide Bore

Intake and exhaust 7.0017.021 mm (0.27570.2764 in.)
Valve Guide Replacement

NOTE: Inexperienced personnel should not attempt to replace the valve guide. A reputable engine machine shop will have the
tools to replace the valve guides and ream the guides to proper tolerance.
IMPORTANT: The head must be heated to a minimum temperature of 350 F before removing or installing the valve guide. Use
a pneumatic impact hammer to remove and install the valve guide. Check the valve guide for proper clearances after
installation.
a - Valve guide height
48351
Cylinder Head
Valve guide height 15.1 0.25 mm (0.595 0.0098 in.)
Valve Stem to Valve Guide Clearance

Intake 0.0230.059 mm (0.00090.0023 in.)
Exhaust 0.0330.069 mm (0.00120.0027 in.)
Valve Seat Reconditioning

The cylinder head is the most important component of the engine. It has extremely close tolerance machined components that
must be repaired by an accomplished Master Technician with experience servicing highperformance engines. A skilled
machine shop that is familiar with automotive engine machining techniques must be utilized when the cylinder head requires
any type of machining or clearance correction repair. Damage to the cylinder head combustion chamber area from a
component failure, debris, or improper machining, will alter the emissions output of the engine and may require the cylinder
head be replaced instead of repaired. Careful attention to details, proven repair techniques, and factory supplied high quality
parts are required to restore this engine to the original factory emissions and performance output.
IMPORTANT: The cylinder head is machined to extremely close tolerances and must not be modified by inexperienced
personnel. Cutting the valve seat without close attention to detail can change the combustion chamber area where the engine
is not within the factory emissions specification and may affect the engine's performance.
1. Clean the carbon deposits from the combustion chambers and valve seats. Check the valve seats for pitting.
2. Minimal and light pitting should be removed with 600 grit lapping compound.
IMPORTANT: The exhaust valve and seat should be replaced if the pitting cannot be removed with a minimal amount of
lapping the valve to the seat. If the valve seat is replaced, the top cut of the valve seat must not go below the combustion
chamber or alter the factory machining of the combustion chamber.
3. Apply a thin, even layer of mechanic's bluing dye (Dykem) onto the valve seat.
4. Insert the valve into the valve guide and lap the valve slowly on the valve seat.
Page 4B-16 90-8M0082471 JULY 2014

Cylinder Head
5. Remove the valve and measure the valve seat contact pattern width.
a- Correct valve seat contact area

b- Valve seat too high
a b c d 20969 c- Valve seat too low
d- Valve seat contact too wide
Valve Face Angle

Intake 45
Exhaust 40
Valve Seat Angles

Intake 30, 44 0.25, 60
Exhaust 25, 39 0.25, 53, 67
Cylinder Head Assembly

Cylinder Head Galley Plug Installation
1. Install new Orings on the galley plugs.
2. Lubricate the threads of the galley plugs with Synthetic Blend 4Stroke Outboard Oil 25W40.
3. Install all the oil and water galley plugs. Tighten the galley plugs to the specified torque.
a a a a - (10 mm) galley plug

b - (30 mm) galley plug
c - (24 mm) galley plug
a
a
55885

139 Galley plug threads 92-8M0078629
Outboard Oil 25W-40

(30 mm) galley plug 55 40.5
90-8M0082471 JULY 2014 Page 4B-17

Cylinder Head
Valve Installation
1. Lubricate the valve guide seal with Synthetic Blend 4Stroke Outboard Oil 25W40.
139
4831

139 Valve guide seal 92-8M0078629
Outboard Oil 25W-40
2. Install the valve guide seal onto the valve guide. Push on the valve guide seal until it is seated on the cylinder head.
48337
3. Lubricate the valve stem with a high quality engine assembly lubricant and push the valve through the valve guide seal.
Engine assembly lubricant can be purchased locally.
4. Place the valve spring and valve spring retainer over the valve stem.
5. Compress the valve spring with a valve spring compressor.
IMPORTANT: Use caution when compressing the valve spring. Do not damage the valve, valve spring retainer, or the
cylinder head.
b a- Valve spring retainer lock (2 each)

a
c b- Valve spring retainer
c- Valve spring
d
d- Valve guide seal
e- Valve (intake and exhaust)
48338
Page 4B-18 90-8M0082471 JULY 2014

Cylinder Head
6. Place the valve spring retainer locks onto the valve. A small amount of 24C with PTFE applied to the valve area will help
retain the locks on the valve.
a a - Valve spring compressor tool

b - Valve spring retainer locks
48303

95 2-4-C with PTFE Installing valve spring retainer locks 92-802859A 1
7. Release the valve spring compressor.
8. Continue to assemble all valves onto the cylinder head.
Camshaft Installation
IMPORTANT: Follow the camshaft installation procedure exactly. Failure to follow the installation procedure of the camshaft
caps could result in damage to the camshaft, camshaft caps, and the cylinder head camshaft bearing area.
1. Lubricate the ball stud assembly threads with Synthetic Blend 4Stroke Outboard Oil 25W40 and install the ball studs onto
the cylinder head.

139 Ball stud assembly threads 92-8M0078629
Outboard Oil 25W-40
2. Verify that the ball stud is threaded completely in to minimize valve spring compression while installing the camshaft.
a a - Ball stud
b - Ball stud nut
55856
3. Verify that the retaining clip is installed on the rocker arm as shown.
a a - Retaining clip
56241
4. Apply Synthetic Blend 4Stroke Outboard Oil 25W40 to the roller bearing on both sides of the rocker arm.
90-8M0082471 JULY 2014 Page 4B-19

Cylinder Head
5. Apply engine assembly lubricant to the ball stud end and valve end of the rocker arm. Engine assembly lubricant can be
purchased locally.
b a - Engine assembly lubricant (obtain locally)

b - Synthetic Blend 4Stroke Outboard Oil 25W40
a a
55880

139 Rocker arm roller bearing 92-8M0078629
Outboard Oil 25W-40
6. Install the rocker arm onto the ball stud and valve.
55855
7. Apply engine assembly lubricant to the camshaft lobes, journals, and thrust face. Engine assembly lubricant can be
purchased locally.
8. Install the camshaft so the camshaft gear pin is located at the 9 o'clock position. This allows the camshaft to have minimal
valve spring tension when installing and tightening the camshaft cap screws.
55970
9. Apply engine assembly lubricant to the cylinder head camshaft caps. Engine assembly lubricant can be purchased locally.
10. Install camshaft cap 2 and 3. Verify that the arrow on the cap points towards the top of the cylinder head.
IMPORTANT: The camshaft cap screws and the threads in the head must be thoroughly cleaned of debris and oil. The
camshaft cap screws must be completely dry when applying the torque.
11. Ensure that the camshaft caps are parallel with the cylinder head mating surface while tightening the screws 1/4 turn each.
Continue to tighten the screws 1/4 turn each until the camshaft caps are seated on the cylinder head. Do not torque the
screws.
Page 4B-20 90-8M0082471 JULY 2014

Cylinder Head
IMPORTANT: Rotating the camshaft cap screws more than 1/4 turn could cause damage to the camshaft, camshaft caps,
and the cylinder head camshaft bearing area.
a - Cap 3
b - Cap 2
a b
55854
12. Install camshaft caps 1, 4, and 5. Verify that the arrow on the cap points towards the top of the cylinder head. Tighten the
screws until the caps are seated on the cylinder head.
13. Tighten the camshaft cap screws in two stages to the specified torque in the sequence shown.
9 5 1 3 7
10 6 2 4 8
55881

First 6 53
Camshaft cap screws (M6 x 35)
Final 12 106
Adjusting Valve Clearance

IMPORTANT: Setting the valve clearance on the bench will not necessarily match the final specification after the cylinder head
has been installed onto the cylinder block and tightened to specification. It is expected that the valve clearance will change to a
value that minimizes the amount of additional adjustment.
IMPORTANT: The valve clearance specifications apply when the ball stud locknut is tightened to the specified torque.
IMPORTANT: When measuring clearance with a feeler gauge blade you must change sizes until you feel a firm drag when
pushing and pulling on the gauge. Verify your results by trying the next size larger blade. It must be much more difficult or
nearly impossible to enter the gap. Next, try the next size smaller blade. It must have little or no drag. If your results are
different, your technique is incorrect. Common mistakes are twisting and flexing the blade, and failing to hold the blade
perpendicular to the gap.
1. Rotate the camshaft so the lobe is 180 from the rocker arm roller.
2. Insert a feeler gauge between the roller and the cam. Increase the ball stud height so there is a slight drag on the gauge.
90-8M0082471 JULY 2014 Page 4B-21

Cylinder Head
3. Secure the ball stud and tighten the locknut to the specified torque.
a - Feeler gauge
a b - Ball stud
c - Locknut
b
c
48342
Camshaft to Roller Clearance Specifications

Intake valve 0.075 mm 0.025 (0.003 in. 0.001 in.)
Exhaust valve 0.150 mm 0.025 (0.006 in. 0.001 in.)

Ball stud locknut 20 177
4. Check the clearance after tightening the locknut to the specified torque. Adust the clearance as required.
Page 4B-22 90-8M0082471 JULY 2014

Lubrication
Powerhead
Section 4C - Lubrication
Table of Contents
Lubrication System Specifications..................................... 4C-2 Disassembly and Inspection.......................................4C-3
Oil Flow Diagram............................................................... 4C-3 Assembly.................................................................... 4C-4
Oil Pump ........................................................................... 4C-3
4
C
90-8M0082471 JULY 2014 Page 4C-1

Lubrication

5.2 L (5.5 US qt) NMMA FCW
Engine capacity with filter replacement
SAE 10W30
Quicksilver P/N 8M0065103
Oil filter
MPP P/N 8M0065104
At idle RPM (normal oil warm) 90180 kPa (1326 psi)
At WOT RPM (normal oil warm) 300400 kPa (43.558 psi)
Oil pressure
At idle RPM (minimum) 35 kPa (5 psi)
At WOT RPM (minimum) 185 kPa (27 psi)

4-Stroke 10W-30 Outboard
110 Oil pump 92-858045K01
Oil
Page 4C-2 90-8M0082471 JULY 2014

Lubrication
Oil Flow Diagram
e
c
i
g
b
a
56276
a- Oil sump
b- Oil pump
c- Cylinder block
d- Cylinder head
e- Ball stud adjusters
f- Camshaft
g- Camshaft chain tensioner
h- Oil filter
i- Crankshaft
j- Connecting rods
Oil Pump
The oil pump is not a serviceable part, but should be disassembled for inspection when the cylinder head or cylinder block is
repaired. The oil pump should also be disassembled and inspected if the engine was submerged in water.
90-8M0082471 JULY 2014 Page 4C-3

Lubrication
1. Remove the eight screws securing the oil pump cover to the oil pump housing in the sequence shown. Remove the cover.
2 7
3
1 8 55459
2. Remove the inner drive gerotor and outside gerotor.

b - Outside gerotor
55471
3. Inspect all areas where the gerotors contact each other and where the gerotors contact the oil pump housing and cover.
The contact areas should be smooth without grooves, galling, or evidence of corrosion.
IMPORTANT: A pressure relief valve is incorporated into the oil pump housing. It should never be removed from the
housing to modify the spring pressure. If significant debris was found in the oil pump gerotor area, the oil pump must be
replaced as an assembly.
Assembly
1. Wash the housing, cover, and gerotors with a mild solvent. Use compressed air to dry the components.
2. Inspect the seal lips for damage. Replace as needed. Lubricate the seal lips with Extreme Grease.

3. Generously lubricate the gerotors and the areas where the gerotors contact the housing and cover with 4Stroke 10W30
Outboard Oil.

4-Stroke 10W-30
110 Oil pump 92-858045K01
Outboard Oil
4. Install the outside gerotor into the oil pump housing with the dot side up.
Page 4C-4 90-8M0082471 JULY 2014

Lubrication
5. Install the inner drive gerotor.

b - Outside gerotor
55471
6. Align the oil pump cover with the oil pump housing pins and install the oil pump cover.
7. Secure the oil pump cover with eight screws. Tighten the screws to the specified torque in the sequence shown.
7 2
6
8 1 55460

Oil pump cover screws (7) 4 35.4
90-8M0082471 JULY 2014 Page 4C-5

Lubrication
Notes:
Page 4C-6 90-8M0082471 JULY 2014

Cooling
Powerhead
Section 4D - Cooling
Table of Contents
Cooling Specifications....................................................... 4D-2 Thermostat.........................................................................4D-8
Cooling Components......................................................... 4D-4 Thermostat Removal.................................................. 4D-8
Water Flow Diagram.......................................................... 4D-7 Thermostat Installation............................................... 4D-9
Troubleshooting................................................................. 4D-7
4
D
90-8M0082471 JULY 2014 Page 4D-1

Cooling
Cooling system Watercooled thermostat control
Water pressure
At 5800 RPM (WOT) 80300 kPa (11.643.5 psi)
Valve stroke (minimum) at full open temperature 7.62 mm (0.30 in.)
Thermostat Start to opening temperature 46.151.7 C (115125 F)
Full open temperature 65.6 C (150 F)

9 Water pump indicator fitting threads 92-809822
Sealant
95 2-4-C with PTFE Thermostat housing O-ring 92-802859A 1
Special Tools
8M0046124
Harness
Provides diagnostic support for the Computer Diagnostic System.
41993
Page 4D-2 90-8M0082471 JULY 2014

Cooling
Notes:
90-8M0082471 JULY 2014 Page 4D-3

Cooling
Cooling Components
4
2 1
3
7
14
5
6
29
13
11
25
22
23 26
22 12 2
27
20 7
21
26
24 28
26
9
8
10
19
18
19
15 17
16 55129
Page 4D-4 90-8M0082471 JULY 2014

Cooling
Cooling Components
Torque
1 1 Hose
2 2 Metal clamp (36.1 mm)
3 1 Thermostat assembly
5 2 Clip
6 1 Hose
7 2 Cable tie
8 1 Water pump indicator
9 1 Oring
10 1 Screw 6 53.1
11 1 Fitting
12 1 Oring
14 1 Strainer
15 1 Exhaust cooling fitting
16 1 Washer
18 1 Sprayer hose
19 2 Cable tie
20 1 Flushing valve
23 1 Tubing (8 mm ID)
24 1 Flush hose
25 1 Fitting
26 4 Cable tie
27 1 Hose
28 1 Hose
29 1 Cable tie clip
90-8M0082471 JULY 2014 Page 4D-5

Cooling
Notes:
Page 4D-6 90-8M0082471 JULY 2014

Cooling
Water Flow Diagram
1- Water intake
9 10
2- Water pump
8 3- Exhaust tube
4- Water strainer
6 5- Exhaust manifold
6- Cylinder head
7- Engine block
9- Water pump indicator
5 fitting with strainer
7
10 - Cooling water bypass
11 11 - Head gasket bypass
12 - Thermostat discharge
20 hose
discharge
15 - Sprayer (located in the
driveshaft housing)
17 18 16 - Through the propeller
discharge
4 17 - Water to block (engine
19
running)
18 - Block drain (engine
12 not running)
14
19 - FSM cooling water
supply hose
20 - Flush hose fitting
13
15 2
16
56274
Troubleshooting
Refer to the following table to aid with cooling system diagnostics.
90-8M0082471 JULY 2014 Page 4D-7

Cooling
Symptom Possible Causes Solution

Thermostat is plugged with debris Inspect the thermostat for debris, corrosion, or
Engine overheating
or stuck closed damage. Replace if necessary.
Inspect the thermostat for debris, corrosion, or
Engine overcools Thermostat is stuck open
damage. Replace if necessary.
Inspect the thermostat for debris, corrosion, or
Idle exhaust relief gushing water Thermostat is stuck open
damage. Replace if necessary.
Fuel pump whines, rough idle, or No water flow to fuel supply Inspect the strainer for debris. Refer to Section 5B
engine stall module Adapter Plate and Driveshaft Housing.
Inspect the water pump indicator strainer for debris.
The strainer is located next to the thermostat
Water pump indicator strainer
Weak water pump indicator flow housing on the top of the powerhead. Refer to
plugged
Thermostat Removal and Thermostat
Installation.
Thermostat
Thermostat Removal
The thermostat can be monitored for proper operation with the CDS G3 tool.
The thermostat can be removed for inspection without removing the thermostat dump hose from the thermostat housing.

8M0046124
Harness
1. Cut the cable tie securing the water pump indicator hose to the fitting on the cylinder head. Remove the hose.
a - Cable tie
b - Water pump indicator hose
a
55085
2. Remove the water pump indicator fitting from the cylinder head.
3. Remove the screws securing the thermostat housing to the cylinder head.
a - Water pump indicator fitting

a b - Screws securing the thermostat housing to the
cylinder block
b
55086
Page 4D-8 90-8M0082471 JULY 2014

Cooling
4. Inspect the strainer on the water pump indicator fitting for debris, damage, or deposits. Clean or replace the fitting as
necessary.

b - Strainer
b
56301
5. With a twisting motion, remove the thermostat housing from the cylinder head.
6. Push down on the thermostat spring retainer and rotate the retainer counterclockwise.
7. Remove the spring and thermostat.
a - Thermostat spring retainer (rotate counterclockwise)

b - Thermostat
b
a
55096
8. Inspect the thermostat and spring for debris, failure, or corrosion. Replace any items that are damaged.
Thermostat Installation
1. Install the narrow end of the thermostat into the thermostat housing.
2. Install the narrow end of the thermostat spring onto the thermostat.
3. Install the thermostat spring retainer onto the spring.
d a- Thermostat housing
b- Thermostat
c
c- Thermostat spring
b d- Thermostat spring retainer
a
48164
90-8M0082471 JULY 2014 Page 4D-9

Cooling
4. Push down on the thermostat spring retainer and rotate the retainer clockwise to lock it onto the thermostat housing.
a - Thermostat spring retainer (rotate clockwise)

b - Thermostat
b
a
55098
5. Install the Oring onto the thermostat housing. Lubricate the Oring with 24C with PTFE.
55100

95 2-4-C with PTFE Thermostat housing O-ring 92-802859A 1
6. Apply Loctite 567 PST Pipe Sealant onto the water pump indicator fitting threads. Ensure that no sealant is applied to the
strainer.

b - Strainer
b
56301

9 Water pump indicator fitting threads 92-809822
Sealant
7. Install the water pump indicator fitting into the cylinder head. Tighten the fitting until 12 threads are exposed and the fitting
is oriented as shown.
Page 4D-10 90-8M0082471 JULY 2014

Cooling
8. Install the thermostat housing onto the cylinder head and secure with two M6 x 25 screws. Tighten the screws to the
specified torque.

a b - M6 x 25 screws (2)
b
55086

Screws (M6 x 25) 10 88.5
9. Install the water pump indicator hose onto the fitting. Secure the hose with a cable tie.
a - Cable tie
b - Water pump indicator hose
a
55085
90-8M0082471 JULY 2014 Page 4D-11

Cooling
Notes:
Page 4D-12 90-8M0082471 JULY 2014

Clamp/Swivel Brackets and Driveshaft Housing
Midsection
Section 5A - Clamp/Swivel Brackets and Driveshaft Housing
Table of Contents
MidSection Specifications.................................................5A-2 Upper Mounts.................................................................. 5A-22
Top Cowl Components...................................................... 5A-4 Removal....................................................................5A-22
Lower Cowl Components...................................................5A-6 Installation.................................................................5A-23
Swivel Bracket and Swivel Pin Components..................... 5A-8 Driveshaft Housing/Adapter Plate Removal.....................5A-26
Transom Bracket Components........................................ 5A-10 Transom and Swivel Bracket........................................... 5A-28
Lower Cowl...................................................................... 5A-12 Transom/Swivel Bracket Disassembly......................5A-28
Lower Cowl Removal................................................5A-12 Swivel Bracket/Steering Arm Disassembly...............5A-30
Lower Cowl Installation.............................................5A-15 Swivel Bracket/Steering Arm Assembly....................5A-31
Hose Routing................................................................... 5A-18 Transom/Swivel Bracket Assembly.......................... 5A-33
Lower Mounts.................................................................. 5A-19
Removal....................................................................5A-19
Driveshaft Housing/Adapter Plate Installation..................5A-36
Shift Shaft Installation............................................... 5A-38 5
A
Installation.................................................................5A-20 Gearcase and Powerhead Installation......................5A-40
90-8M0082471 JULY 2014 Page 5A-1

Recommended Transom Height
Short Shaft 51 cm (20 in.)
Long Shaft 64 cm (25 in.)
Steering Pivot Range 60
Full Tilt Up Angle 71
Allowable Transom Thickness (Max) 76.2 mm (3 in.)

Steering arm assembly
Neutral detent groove and shift shaft spline
95 2-4-C with PTFE 92-802859A 1
Detent ball
Inside and outside diameters of the shift shaft bushing
Special Tools

14869
Page 5A-2 90-8M0082471 JULY 2014

Notes:
90-8M0082471 JULY 2014 Page 5A-3

Top Cowl Components

1
5 6
8 7
13
12
9 11 10
4
3
3
2
14
55117
Page 5A-4 90-8M0082471 JULY 2014

Top Cowl Components

Torque
1 1 Top cowl assembly
2 1 Top front hook
3 4 Screw (M6 x 12) 10 88.5
4 4 Washer
5 1 Slotted spring pin
6 1 Latch handle
7 1 Rear latch link
8 1 Rear latch seal
9 1 Snap clip
10 1 Latch assembly
11 2 Washer
12 2 Screw (M6 x 16) 10 88.5
13 1 Retainer
14 1 Top cowl seal
90-8M0082471 JULY 2014 Page 5A-5

Lower Cowl Components

1
7
5
3
4
17 8
6
16
18
2
15
1
13 2
14
19
10
12
11 10 9
2
12
20
26 22
23
21
27
24
25
28
10 28
28
55118
Page 5A-6 90-8M0082471 JULY 2014

Lower Cowl Components

Torque
1 Top cowl seal
1 1 Starboard and port lower cowl assemblies
2 2 Screw (M6 x 25) 6 53
3 1 Retainer
4 1 Trim switch bezel
5 1 Tether
6 1 Fitting
7 1 Seal
8 1 Plug
9 1 Front lower cowl assembly
10 4 Screw (M6 x 20) 6 53
11 1 Retainer
12 2 Shoulder screw (M6 x 12) 6 53
13 1 Starboard upper mount cover
14 1 Port upper mount cover
15 2 Washer
16 2 Screw (M6 x 25) 6 53
17 1 Striker assembly
18 1 Screw (M6 x 45) 6 53
19 1 Ingress mounting plate
20 3 Button head screw (M5 x 8) 6 53
21 1 Trim harness grommet
22 1 Ingress grommet
23 1 Hose rigging adapter
24 1 Flange head screw (M6 x 50) 8 71
28 3 Screw (M6 x 25) 6 53
90-8M0082471 JULY 2014 Page 5A-7

Swivel Bracket and Swivel Pin Components

12
9 8
3
11
10 4 2 1
10 5
7
2
3 5
1
13
14
15
20
19
33 18
17
16
16
32
15 15
14 26 27
21 13 25 3 28 29 30
22 23
31
24 3
55140
Page 5A-8 90-8M0082471 JULY 2014

Swivel Bracket and Swivel Pin Components

Torque
1 2 Flange head screw (M12 x 120)
2 2 Washer
3 12 Screw (M8 x 30) 27.1 20
4 2 Upper mount assembly
5 2 Upper mount cover
6 2 Locknut (M12) 68 50.2
7 1 Swivel tube assembly
8 1 Link rod assembly
9 1 Screw (0.37524 x 1.5) 54.2 40
10 2 Brass nut (0.37524)
11 2 Washer
12 1 Cable tie
13 2 Thrust washer
14 2 Seal
15 2 Bushing
16 2 Bushing
17 1 Trim sensor assembly
18 2 Washer
19 2 Lockwasher
20 2 Screw (#1024 x 0.750) 1.7 15
21 2 Screw (M12 x 120)
22 2 Washer
23 1 Bottom yoke
24 1 Retaining ring
25 1 Snubber
26 2 Lower mount assembly
27 2 Lower mount cover
28 2 Snubber washer
29 2 Washer
30 2 Locknut (M12) 68 50.2
31 1 Cable assembly
32 1 Cable assembly
33 1 Swivel bracket
90-8M0082471 JULY 2014 Page 5A-9

Transom Bracket Components

2 1 3 4 8 9
10
11 7
16 4 5 11
6
20 19 12
13 14 15
20 19
17
18 18
17
18
17
19 20 17
21 18 16 20
19
23
22
24 21
22
25
26
27
55142
Page 5A-10 90-8M0082471 JULY 2014

Transom Bracket Components

Torque
1 1 Knob
2 1 Goove pin
3 1 Spring
4 2 Nylon bushing
5 1 Tubing
6 1 Spring
7 1 Pin
8 1 Nylon insert nut (1.0014) 62 45.7
9 1 Oring
10 1 Tilt tube
11 2 Washer
68, then 50.2, then
12 1 Nut (0.87514) back off back off
90 90
13 1 Cclip
14 2 Clip
15 1 Screw (#1016 x 0.600)
16 1 Grease fitting
17 4 Screw (0.50020 x 4.500)
18 4 Washer
19 4 Washer
20 4 Nut (0.50012)
21 6 Screw (M10 x 30) 54.2 40
22 6 Washer
23 1 Nut (M10)
24 1 Anchor bracket
25 1 Anode
26 2 Washer
27 2 Screw (M6 x 25) 8 71
90-8M0082471 JULY 2014 Page 5A-11

Lower Cowl
Lower Cowl Removal
! WARNING
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.
IMPORTANT: Do not remove the two screws securing the lower cowl latch striker or the four screws securing the top cowl latch
hook.
a b a - Lower cowl latch striker

b - Top cowl latch hook
55811

2. Remove the fuel line, remote control harness, the throttle cable, and the shift cable.
3. Disconnect the cowl trim switch harness connector.
4. Remove the electrical plate cover.
5. Remove the grommet securing the trim motor wire harness and trim sender wire harness to the starboard cowl.
a a - Cowl trim switch

harness connector
b - Grommet
c - Electrical plate cover
c
54834
6. Cut the cable ties securing the power trim position sensor and motor wires.
7. Disconnect the power trim wire bullet connectors.
Page 5A-12 90-8M0082471 JULY 2014

8. Pull the wires down through the starboard cowl.
a - Cable tie
c b - Cable tie
c - Power trim position sensor (3) and
power trim motor (2) wire bullet
connectors
a
b
54837
9. Rotate the freshwater flush retainer counterclockwise to remove it from the cowl.
10. Remove the freshwater flush hose adapter from the retainer.
11. Remove the freshwater flush retainer from the tether.
12. Push the flush hose back inside the cowl and attach the retainer.
c a
b
54836
a - Freshwater flush retainer

b - Tether
c - Freshwater flush hose adapter
13. Remove the three screws securing the front lower cowl latch retainer.
14. Remove the cowl seal from the port lower cowl all the way past the rear cowl latch.
a- Front lower cowl latch retainer

a b- Flange head screw (M6 x 25) (2)
c- Flange head screw (M6 x 20)
d- Cowl seal
c
d
54838
90-8M0082471 JULY 2014 Page 5A-13

15. Remove the two screws securing the front lower cowl to the starboard cowl.
a - Front lower cowl

a b - Flange head screw (M6 x 25)
c - Flange head screw (M6 x 20
54839
16. Remove the two starboard side screws securing the starboard cowl to the rear cowl latch assembly and port cowl.
a - Rear cowl latch assembly

b - Flange head screw (M6 x 45 stainless steel)
a
c - Flange head screw and washer (M6 x 25)
54840
17. Remove four screws securing the front of the port side cowl to the starboard side cowl.
18. Remove the three screws securing the rear of the port side cowl to the starboard side cowl.
19. Remove the upper screw securing the rear of the port side cowl to the starboard side cowl.
20. Remove the flange head shoulder screws securing the port and starboard upper mount covers.
Starboard
a - Flange head screw (M6 x 85)
b - Flange head screw (M6 x 70)
e c - Flange head screw (M6 x 20)
h d d - Flange head screw (M6 x 25) (4)
e - Flange head shoulder screw (M6 x 16) (2) (starboard shown)
f f - Upper mount cover (2) (starboard shown)
a g - Engine oil drain valve
h - Water pump indicator tube
g d
b
c d
54841
21. Remove the port side cowl.
Page 5A-14 90-8M0082471 JULY 2014

22. Remove the starboard side cowl ensuring that the oil drain valve does not scrape the cowl.
23. Remove the port and starboard upper mount covers.
Lower Cowl Installation

IMPORTANT: Apply Loctite 242 Threadlocker to all the screw threads used in this procedure.
Do not fully tighten the screws until both cowls and all hardware are aligned.
1. Ensure that the adapter plate seal is properly installed.
2. Ensure that the muffler grommet is installed.
3. Lubricate the adapter plate seal with liquid detergent. Do not use a petroleumbased product to lubricate the seal.
a - Muffler grommet
b - Adapter plate seal
c - Water pump indicator tube
a
c
b 54842
4. Install the port and starboard upper mount covers onto the lower cowls. Ensure that the cowls are aligned with the upper
mount covers. Use a round piece of metal stock to help align the cover with the cowl. Use caution not to damage the cowl
or cover.
5. Guide the starboard side cowl over the oil drain valve and water pump indicator tube, and install the starboard cowl onto
the adapter plate seal.
NOTE: The top cowl seal remained attached to the starboard cowl in this procedure.
6. Guide the port cowl with the front lower cowl attached onto the adapter plate seal.
7. Ensure that the cowls are aligned with the muffler grommet.
8. Install the cowl screws as shown.
Starboard
a - Flange head screw (M6 x 85)
e c - Flange head screw (M6 x 20)
h d d - Flange head screw (M6 x 25) (4)
e - Flange head shoulder screw (M6 x 16) (2) (starboard shown)
f f - Upper mount cover (2) (starboard shown)
a g - Engine oil drain valve
h - Water pump indicator tube
g d
b
c d
54841
90-8M0082471 JULY 2014 Page 5A-15

9. Install the two starboard side screws securing the starboard cowl to the rear cowl latch assembly and port cowl.
a - Rear cowl latch assembly

b - Flange head screw (M6 x 45 stainless steel)
a
c - Flange head screw and washer (M6 x 25)
54840
10. Install the two screws securing the front lower cowl to the starboard cowl.
a - Front lower cowl

a b - Flange head screw (M6 x 25)
c - Flange head screw (M6 x 20
54839
11. Install the three screws securing the top cowl latch retainer. Tighten the screws to the specified torque.
12. Starting at the rear center of the port cowl, install the cowl seal. Use a rubber hammer to lightly tap on the seal to ensure it
is fully seated on the cowling.
a- Top cowl latch retainer

a b- Flange head screw (M6 x 16) (2)
c- Flange head screw (M6 x 20)
d- Cowl seal
c
d
54838

M6 top cowl latch retainer flange head screws 8 71
13. Route the flush hose through the cowl and attach the retainer to the tether.
Page 5A-16 90-8M0082471 JULY 2014

14. Install the retainer into the cowl.
d
c b a
55807
a- Freshwater flush retainer

b- Tether
c- Freshwater flush hose adapter
d- Freshwater flush hose
15. Route the power trim wires/harnesses through the starboard cowl.
16. Connect the power trim wire bullet connectors.
17. Securing the power trim position sensor and motor wires with cable ties.
a - Cable tie
c b - Cable tie
c - Power trim position sensor (3) and
power trim motor (2) wire bullet
connectors
a
b
54837
18. Connect the cowl trim switch harness connector.

19. Install the electrical plate cover.
90-8M0082471 JULY 2014 Page 5A-17

20. Install the grommet securing the trim motor wire harness and trim sender wire harness into the starboard cowl.
a a - Cowl trim switch

harness connector
b - Grommet
c - Electrical plate cover
c
54834
21. Install the fuel line, remote control harness, the throttle cable, and the shift cable.
22. Verify all of the cowl mating components are properly aligned.
23. Tighten all of the cowl M6 screws to the specified torque.

M6 flange head screws 6 53
24. Install the throttle and shift cables, fuel line, and remote control harness. Refer to Section 1D Electrical, Fuel Hose, and
Control Cables.
25. Connect the battery cables to the battery.
Hose Routing
f
e
a
d c
c 55070
Port side Starboard side

a - Water strainer
b - Water strainer
c - Fuel supply module
d - Fuel supply module
e - Water pump indicator
f - Speedometer hose
Page 5A-18 90-8M0082471 JULY 2014

Lower Mounts
Removal
1. Remove the lower cowls. Refer to Section 5A Lower Cowl Removal.
2. Trim the engine to 2030.
3. Remove the two screws securing the port lower mount cover.
Port side
a - Cover
a b - Screw (M8 x 30 flange head) (2)
55042
4. Remove the port lower mount locknut and bolt.

5. Remove the ground cable from the bolt.
6. Remove the lower port mount from the driveshaft housing.
j i Port side
a - Bolt (M12 x 120)
h b - Washer
c - Snubber
d - Lower mount
e - Snubber washer
f - Washer
g - Locknut (M12)
h - Ground cable
i - Screw
a g j - Ground cable
b c d e f
55043
7. Remove the starboard lower mount cover.

8. Remove the starboard lower mount locknut and bolt.
9. Remove the snubber.
90-8M0082471 JULY 2014 Page 5A-19

10. Remove the starboard lower mount from the driveshaft housing.
a Starboard side
b a - Screw (M8 x 30 flange head) (2)
b - Cover
c - Bolt (M12 x 120)
d - Locknut (M12)
c
56177
Installation
1. Trim the engine to 2030.
2. Ensure that the mounting surfaces are clean.
55044
Port side
3. Place the lower mount into the pocket in the driveshaft housing.
4. Install the snubber onto the lower mount between the lower mount and the lower yoke.
5. Install a washer and an M12 x 120 bolt through the yoke and lower mount (port side shown).
Page 5A-20 90-8M0082471 JULY 2014

6. Install the snubber washer. Align the notches on the snubber washer with the tabs on the lower mount.
Port side
a - Bolt (M12 x 120)
g b - Washer
c - Lower yoke
d - Snubber
e - Lower mount
f - Snubber washer
a g - Notches on snubber washer
b
c d e f
55053
7. Install the steel washer and ground cable (port side only).
8. Install the locknut. Do not tighten at this step.
e d Port side
a - Washer
b - Locknut (M12)
c - Ground cable
d - Screw
c e - Ground cable
a b
55054
9. Install the lower mount cover.

10. Tighten the cover screws to the specified torque.
NOTE: Position the ground cable terminal on the bolt so it points horizontally away from the driveshaft housing.
11. Tighten the M12 locknut to the specified torque.
IMPORTANT: To achieve the proper clamp load of the upper and lower mounts, apply torque to the M12 locknut not the
bolt head.
a - Cover
b - Ground cable terminal
c - Screw (M8 x 30 flange head) (2)
b
c
55810
90-8M0082471 JULY 2014 Page 5A-21


Lower mount cover screw (M8 x 30 flange head) 27.1 20
Lower mount locknut (M12) 68 50.2
12. Repeat the installation procedure for the starboard side lower mount. The installation procedure is similar except for the
ground cable.
13. Install cowls. Refer to Section 5A Lower Cowl Installation.
Upper Mounts
Removal
IMPORTANT: The powerhead must be supported during the upper mount removal and installation.
NOTE: The starboard side upper mount must be removed prior to removing the port side upper mount.
1. Remove the upper cowl. Install a lifting ring onto the flywheel.
2. Remove the lower cowls. Refer to Section 5A Lower Cowl Removal.
3. Support the powerhead with a hoist during the upper mount removal and installation.

4. Loosen the starboard side upper mount M12 locknut.
5. Remove the four upper mount cover screws. Remove the cover.
Starboard side
a - M12 locknut
b a
b - Cover
55055
6. Remove the M12 locknut.

7. Pull the bolt through the steering arm yoke.
8. Remove the upper mount, snubber washer, washer, and bolt.
c Starboard side
b a a - M12 locknut
b - Steering arm yoke
c - Upper mount
d
d - Bolt (M12 x 120 flange head)
55060
9. Loosen the port side upper mount M12 locknut.
Page 5A-22 90-8M0082471 JULY 2014

10. Remove the four upper mount cover screws. Remove the cover.
Port side
a - M12 locknut
a b b - Cover
55061
11. Remove the M12 locknut.

12. Loosen both of the lower mount M12 locknuts enough so the tip of the bolt is flush with the nut. This allows the driveshaft
housing to pivot to remove the port side upper mount bolt.
13. Pull the driveshaft housing rearward and rotate it counterclockwise.
14. Pull the port side upper mount bolt through the steering arm yoke.
15. Remove the upper mount, snubber washer, washer, and bolt.
c Port side
a b a - M12 locknut
c - Upper mount
55062
Installation
1. Install the snubber washer onto the upper mount as shown.
2. Install the washer onto the M12 x 120 flange head bolt.
90-8M0082471 JULY 2014 Page 5A-23

3. Install the bolt through the upper mount.
b c d a- Bolt (M12 x 120 flange head)

a
b- Washer
c- Snubber washer
d- Longer end of mount
55063
4. Ensure that the port side mounting surfaces are clean.
55064
Port side
5. Pull the driveshaft housing rearward and rotate it counterclockwise.

6. Install the upper mount into the pocket on the port side of the adapter plate and push the bolt through the steering arm
yoke.
7. Ensure that the tab on the mount fits flush in the notch in the adapter plate. Ensure that the flat on the mount is flush
against the shoulder on the steering arm yoke.
Page 5A-24 90-8M0082471 JULY 2014

8. Install the M12 locknut. Do not torque at this step.
c
a b
55065
Port side
a - M12 locknut
c - Upper mount tab
9. Install the cover and the four M8 bolts. Tighten the bolts to the specified torque.
bolt head.
Port side
a - M12 locknut
a b b - Cover
55061

Locknut (M12) 95 70
11. Ensure that the starboard side mounting surfaces are clean.
12. Install the upper mount into the pocket on the starboard side of adapter plate and push the bolt through the steering arm
yoke.
13. Ensure that the tab on the mount fits flush in the notch in the adapter plate. Ensure that the flat on the mount is flush
against the shoulder on the steering arm yoke. Refer to the port side mount for detail.
90-8M0082471 JULY 2014 Page 5A-25

14. Install the M12 locknut. Do not torque at this step.
Starboard side
b a a - M12 locknut
c - Upper mount tab
d
c
55066
15. Install the cover and the four M8 bolts. Tighten the bolts to the specified torque.
bolt head.
Starboard side
a - M12 locknut
b a
b - Cover
55055

Locknut (M12) 95 70
17. Tighten the lower mount M12 locknuts to the specified torque.
bolt head.

18. Install the lower cowls. Refer to Section 4A Lower Cowl Installation.
Driveshaft Housing/Adapter Plate Removal

1. Remove the powerhead. Refer to Section 4A Dressed Powerhead Removal.
2. Remove the gearcase housing. Refer to Section 6A Gearcase Removal.
3. Drain the engine crankcase oil. Refer to Section 1B Changing Engine Oil.
Page 5A-26 90-8M0082471 JULY 2014

4. Remove the shift shaft assembly from the driveshaft housing/adapter plate by pulling straight up on the shaft.
a - Shift shaft assembly

a
55091
5. Remove the locknuts securing each lower mount to the bottom yoke.
6. Remove the locknuts securing each upper mount to the steering arm.
7. Remove the screw securing the cables to the driveshaft housing. Remove the cable to the lower mount.
a a
c
b a
a b 55092
a - Locknut (M12) (4)

b - Flat washer
c - Screw (M6 x 10)
8. Push the bolts partially through the port and starboard upper mounts.
9. Remove the starboard upper mount bolt.
90-8M0082471 JULY 2014 Page 5A-27

10. Pull the driveshaft housing/adapter plate away from the swivel bracket assembly.
a - Starboard upper mount bolt

b - Swivel bracket assembly
55093
Transom and Swivel Bracket

Transom/Swivel Bracket Disassembly
1. Trim to full up position. Engage the tilt lock lever.
a - Tilt lock knob

b - Tilt lock lever
a
55174
2. Remove the Jclip securing the trim position sensor and power trim motor harnesses.
3. Remove the two screws securing the trim position sensor. Remove the trim position sensor.
a- Trim sensor
b- Trim sensor mounting screw (2)
c- Screw (#10 x 5/8), clamp, and 2 Jclips
a d- Trim sensor and power trim motor
harnesses
d
b
c
55175
Page 5A-28 90-8M0082471 JULY 2014

4. Remove the trilobe pin from the power trim cylinder rod eye.
a - Trilobe pin
b - Rod eye
55176
5. Remove the rod eye pin. Retract the power trim cylinder rod.
6. Inspect the upper pivot pin bearings.
NOTE: Do not remove the bearings unless replacement is required.
If the bearings require replacement:
a. Remove the bearings using a drift punch.
b. Install the bearings flush with the inside wall of the swivel bracket.
a - Upper pivot pin bearings

a b - Bearing flush with the inside wall
b
55177
7. Remove the 11/4 in. hex nut from the tilt tube.
8. Support the swivel bracket while removing the tilt tube from the transom bracket/swivel bracket assembly.
90-8M0082471 JULY 2014 Page 5A-29

9. Remove the swivel bracket and washers.
c a- Starboard transom bracket

b b- Swivel bracket
a d c- Steering arm assembly
d- Port transom bracket
e- Tilt tube
f- 11/4 in. hex locknut (0.87514)
g- 13/8 in. hex locknut (1.00014)
h- Wave washer
e
g
f h h 55178
Swivel Bracket/Steering Arm Disassembly

1. Remove the retaining ring from the bottom of the steering arm assembly.
2. Remove the bottom yoke from the steering arm assembly.
a- Swivel bracket
b- Bottom yoke
c- Retaining ring
d- Steering arm assembly
a
d 55179
3. Remove the steering arm assembly from the swivel bracket.

4. Remove the bushings and seals from the top and bottom of the swivel bracket.
5. Do not remove the upper pivot pin bearings unless they are damaged.
Page 5A-30 90-8M0082471 JULY 2014

6. Remove old grease from the swivel bracket bore and clean the bore.
a a- Seal
b- Swivel bushing
d b c- Swivel bracket
d- Upper pivot pin flange bearing
b
a 55820
Swivel Bracket/Steering Arm Assembly

1. Install a new bushing and seal, spring side up (out), in the top of the swivel bracket.
NOTE: The white dot on the seal indicates the spring side.
a b a - Swivel bracket
b - Seal
c c - Bushing
55181
90-8M0082471 JULY 2014 Page 5A-31

2. Install a new bushing and seal, spring side down (out), in the bottom of the swivel bracket.
a - Swivel bracket
b - Seal
c - Bushing
a
c
b
55182
3. Install the thrust washer on the steering arm assembly.
a - Steering arm assembly

b - Thrust washer
a
55183
4. Install the steering arm assembly into the swivel bracket.

5. Install the thrust washer over the steering arm assembly.
a - Swivel bracket
b - Thrust washer
c - Steering arm assembly
b
a
c
55184
6. Align the bottom yoke mount with the upper mount on the steering arm assembly and assemble the bottom yoke onto the
steering arm assembly.
Page 5A-32 90-8M0082471 JULY 2014

7. Using a suitable mandrel, install the retaining ring in the groove on the steering arm assembly.
a- Swivel bracket
b- Bottom yoke
c- Retaining ring
d- Steering arm assembly
a
d 55179
8. Lubricate the steering arm assembly through the grease fitting in the swivel bracket.
55830

95 2-4-C with PTFE Steering arm assembly 92-802859A 1
Transom/Swivel Bracket Assembly

1. Thread the large nut onto the port end of the tilt tube until it bottoms on the shoulder.
2. Tighten the large nut to the specified torque.
3. Assemble the swivel bracket/steering arm assembly and wave washers between the transom brackets.
4. Insert the tilt tube through the transom brackets and the swivel brackets.
5. Thread the small nut onto the starboard end of the tilt tube.
90-8M0082471 JULY 2014 Page 5A-33

6. Tighten the small nut to the specified torque.
c a- Starboard transom bracket

b b- Swivel bracket
a d c- Steering arm assembly
d- Port transom bracket
e- Tilt tube
f- 11/4 in. hex locknut (0.87514)
g- 13/8 in. hex locknut (1.014)
h- Washer
e
g
f h h 55178

Tilt tube locknut (13/8 in. hex) 62 46
First 68 50
Tilt tube locknut (11/4 in. hex)
Final Then back off 90
7. Align the power trim cylinder rod eye and the swivel bracket cross holes.
NOTE: The chamfered hole in the rod eye faces aft.
8. Insert the upper pivot pin, with the slotted end inserted first, through the swivel bracket and power trim cylinder rod eye.
IMPORTANT: The slotted end of the pivot pin faces port.
a - Slotted end of pivot pin

b - Chamfered hole of rod eye
b
55258
9. Insert a punch into the trim cylinder rod eye to align the cross hole in the upper pivot pin.
Page 5A-34 90-8M0082471 JULY 2014

10. Install the trilobe pin into the upper pivot pin and trim cylinder rod eye.
a a- Upper pivot pin (slot is in line with cross hole)

b- Chamfered hole in rod eye (faces aft)
c- Trilobe pin
d- Trim ram
c b
9201
11. Route the trim position sensor and power trim motor harnesses through the hole in the starboard transom bracket. The
cable tie should be flush with the inside of the transom bracket.
a - Trim position sensor harness

b - Cable tie
c - Power trim motor harness
a
55832
12. Secure the harnesses with two Jclips and a screw.

13. Install the trim position sensor onto the swivel bracket with the potted surface away from the swivel bracket and secure with
two screws. Tighten to the specified torque.
a- Trim position sensor

b- Sensor mounting screw (2)
a c c- Screw (#10 x 5/8), clamp, and 2 Jclips
d- Trim position sensor and power trim motor harnesses
55833

Trim position sensor mounting screws 1.7 15
14. Connect the power trim motor leads to the relay harness.
90-8M0082471 JULY 2014 Page 5A-35

Driveshaft Housing/Adapter Plate Installation

1. Install a washer onto each lower mount bolt.
2. Install the lower mount bolts through the lower yoke.
3. Install the snubber onto the lower mount bolts.
a a- Lower yoke
b- Bolt (M12 x 120) (2)
c- Washer
d- Snubber
c d
55265
4. Install the washers and locknuts onto the starboard upper mount bolts.
5. Install the starboard upper mount bolt through the mount.
6. Install the driveshaft housing/adapter plate onto the steering arm assembly.
a- Starboard upper mount bolt

b- Swivel bracket assembly
c- Lower mount bolt
d- Washer
e- Snubber
e d
55259
7. Install the bolts through the lower mounts.

8. Position the snubber onto the lower mounts.
9. Install the cable onto the port lower mount bolt.
10. Secure the two cables to the driveshaft housing.
11. Install the washers and locknuts onto the lower mount bolts.
Page 5A-36 90-8M0082471 JULY 2014

IMPORTANT: When tightening the locknut, ensure that the cable terminal is pointed away from the driveshaft housing.
a b Port side
a - Cable
b - Screw
c c - Cable
d - Locknut
e - Washer
h f - Snubber washer
g - Snubber
d h - Bolt (M12 x 120)
g f e
55262
12. Tighten the upper and lower mount locknuts to the specified torque.
a a
c
b a
a b 55092
a - Locknut (M12) (4)

b - Flat washer
c - Screw (M6 x 10)

Upper mount locknut (M12) 95 70
90-8M0082471 JULY 2014 Page 5A-37

Shift Shaft Installation

The shift shaft assembly has a neutral position detent. The shift shaft has a machined groove that the detent ball drops into
when in neutral. A slight resistance is felt when shifting into and out of neutral to the forward or reverse gears.

b - Detent notch
c - Neutral detent assembly
a
b
49567
1. Ensure that the gear shift is in neutral.

2. Apply 24C with PTFE to the neutral detent groove and shift shaft splines.
a a - Neutral detent groove

b - Shift shaft splines
95
b 13068

95 2-4-C with PTFE Neutral detent groove and shift shaft spline 92-802859A 1
3. Inspect the detent ball for signs of galling or metal debris. Ensure that the detent ball operates freely. If signs of wear
appear, inspect the shift shaft.
4. Clean the detent assembly and lubricate the detent ball end with 24C with PTFE.
a a - Neutral detent assembly

b - Detent ball
b
49568

95 2-4-C with PTFE Detent ball 92-802859A 1
Page 5A-38 90-8M0082471 JULY 2014

5. Install the detent assembly into the adapter plate. Tighten the detent assembly to the specified torque.
49554

Shift detent assembly 20 177
6. Lubricate the inside and outside diameters of the shift shaft bushing with 24C with PTFE.
7. Push or lightly tap the shift shaft bushing into the bore in the adapter plate.
a - Shift shaft bushing
49647

95 2-4-C with PTFE Inside and outside diameters of the shift shaft bushing 92-802859A 1
8. Install the shift shaft through the bushing in the adapter plate.
NOTE: The final shift shaft orientation is verified during the powerhead/shift bracket installation.
a
b b - Bushing
48221
90-8M0082471 JULY 2014 Page 5A-39

Gearcase and Powerhead Installation

1. Install the gearcase housing. Refer to Section 6A Gearcase Installation.
2. Install the powerhead. Refer to Section 4A Dressed Powerhead Installation.
Page 5A-40 90-8M0082471 JULY 2014

Adapter Plate and Driveshaft Housing
Midsection
Section 5B - Adapter Plate and Driveshaft Housing
Table of Contents
Adapter Plate Components................................................5B-4 Driveshaft Housing/Adapter Plate Disassembly....... 5B-12
Oil Sump Components.......................................................5B-6 Adapter Plate/Oil Sump............................................ 5B-15
Driveshaft Housing Components....................................... 5B-8 Exhaust Tube............................................................5B-17
Exhaust Components.......................................................5B-10 Assembly......................................................................... 5B-19
Preparing Outboard for Adapter Plate Disassembly........ 5B-12 Adapter Plate/Oil Sump............................................ 5B-19
Disassembly.....................................................................5B-12 Driveshaft Housing/Adapter Plate Assembly............ 5B-21
5
B
90-8M0082471 JULY 2014 Page 5B-1


Water strainer screw threads
Flange head screw (M6 x 16) (M6 x 12)
Flange head screw (M6 x 40) (10)
Flange head screw (M6 x 25)
Adapter plate mounting screws (M10 x 60 flange head) (8)
Exhaust tube mounting bolt (M6 x 12 flange head)
Page 5B-2 90-8M0082471 JULY 2014

Notes:
90-8M0082471 JULY 2014 Page 5B-3

Adapter Plate Components

1
8 8
55135
Page 5B-4 90-8M0082471 JULY 2014

Adapter Plate Components

Torque
1 1 Gasket
2 1 Seal
3 1 Adapter plate
6 2 Grommet
7 2 Dowel pin
8 2 Cowl drain
90-8M0082471 JULY 2014 Page 5B-5

Oil Sump Components
8
7
6 9
5 4
55136
Page 5B-6 90-8M0082471 JULY 2014

Oil Sump Components

Torque
1 2 Dowel pin
2 1 Gasket driveshaft housing to adapter plate
3 1 Oil sump
4 8 Flange head bolt (M6 x 40) 10 88.5
5 1 Oil drain valve 15 133
6 1 Oring
7 1 Oring
8 1 Oring
9 1 Oil sump grommet
90-8M0082471 JULY 2014 Page 5B-7

Driveshaft Housing Components

11
10
12
9
12
6
55145
7
Page 5B-8 90-8M0082471 JULY 2014

Driveshaft Housing Components

Torque
1 1 Driveshaft housing assembly (long)
2 1 Screw (M8 x 30)
3 1 Screw (M6 x 10)
5 4 Stud (M12 x 52) 30 22
6 4 Washer
7 4 Locknut (M12) 60 44
8 1 Grommet
9 2 Cable clamp
10 1 Speedometer hose
11 1 Connector
12 4 Chap support cap
90-8M0082471 JULY 2014 Page 5B-9

Exhaust Components
1
3 2
5
14
6 15
16
7
13
17
11
10 12
55139
Page 5B-10 90-8M0082471 JULY 2014

Exhaust Components
Torque
1 1 Idle relief muffler
2 1 Grommet
3 1 Grommet
4 1 Grommet
5 1 Oring
6 1 Oring
7 1 Flange seal
8 1 Exhaust pipe assembly
9 1 Water tube grommet
10 1 Grommet
11 1 Water tube
12 1 Water tube grommet
13 1 Flange head screw (M6 x 25) 10 88.5
14 1 Strainer assembly
15 1 Seal
17 1 Seal
90-8M0082471 JULY 2014 Page 5B-11

Preparing Outboard for Adapter Plate Disassembly

1. Remove the powerhead. Refer to Section 4A Dressed Powerhead Removal.
2. Remove the driveshaft housing/adapter plate from the swivel bracket assembly. Refer to Section 5A Driveshaft
Housing/Adapter Plate Removal.
NOTE: The adapter plate may be removed without removing the driveshaft housing from the swivel bracket assembly.
Remove the through bolts from the upper mounts.
3. Remove the fuel supply module. Refer to Fuel Supply Module (FSM).
Disassembly
Driveshaft Housing/Adapter Plate Disassembly
NOTE: The adapter plate may be removed without removing the driveshaft housing/adapter plate assembly from the swivel
bracket assembly. Remove the through bolts from the upper mounts.
NOTE: The driveshaft housing may also be removed without removing the driveshaft housing/adapter plate assembly from the
swivel bracket assembly. Remove the through bolts from the lower mounts. This provides access to the oil sump and adapter
plate components.
1. Remove the speedometer tube from the fitting on the driveshaft housing.
2. Remove the fuel supply module (FSM) water supply and block drain hoses from the water strainer.
55281
a - Speedometer tube and fitting

b - Water strainer FSM water supply hose
c - Water strainer block drain hose
Page 5B-12 90-8M0082471 JULY 2014

3. Remove the two plastic screws and Jclips.
a - Plastic screw and Jclip (2)

b - Inlet fuel hose
c - Speedometer tube
c
b
56180
4. Pull the adapter plate seal up and remove the speedometer tube from the seal and adapter plate.
5. Push the inlet fuel hose grommet through the adapter plate and remove the hose.
6. Pull the water strainer hose grommets up through the adapter plate and remove the hoses.
a a- Speedometer hose
b- Adapter plate seal
c- FSM fuel line grommet
d- Water strainer block drain hose
e- Water strainer FSM water supply hose
b
c
55282
7. Remove the oil drain valve and the grommet.

8. Remove the M6 x 12 flange head screw and washer securing the exhaust cooling fitting to the driveshaft housing.
a- Grommet
b- Oil drain valve
c- Exhaust cooling fitting
d- Flange head screw (M6 x 12)
a
b
c
d
55283
90-8M0082471 JULY 2014 Page 5B-13

9. Inspect the oil drain valve Orings. Replace if necessary.
48459
10. Remove the eight M10 x 60 flange head screws securing the adapter plate to the driveshaft housing.
a
55314
a - Flange head screw (M10 x 60) (8)
11. Remove the adapter plate from the driveshaft housing.
a - Adapter plate
b - Dowel pin (2)
c - Driveshaft housing
a
b b
c
55317
NOTE: If the dowel pins remain in the driveshaft housing, remove and install into the adapter plate.
Page 5B-14 90-8M0082471 JULY 2014

Adapter Plate/Oil Sump

Disassembly
1. Remove the screw securing the exhaust tube to the adapter plate. Remove the exhaust tube.
a - Exhaust tube
a
b
55318
2. Remove the ten flange head screws securing the oil sump to the adapter plate.
3. Remove the oil sump.
4. Remove the gasket.
a - Flange head screw (M6 x 40) (10)

b - Oil sump
c - Adapter plate to driveshaft housing gasket
a
c
55319
5. Inspect the adapter plate seal.

6. Inspect the grommets and cowl drains.
90-8M0082471 JULY 2014 Page 5B-15

7. Inspect the shift shaft bushing.
d b
e g
a
55342
a- Adapter plate seal

b- Shift shaft bushing
c- Idle relief muffler grommet
d- Grommet
e- Cowl drain
f- Fuel supply module seal
g- Dowel pin
8. Inspect the water dump fitting and the tell tale assembly.
b
a
55344
a- Water dump fitting

b- Flange head screw (M6 x 12)
c- Tell tale assembly
Page 5B-16 90-8M0082471 JULY 2014

Exhaust Tube
1. Remove and replace both exhaust tube Orings.
2. Inspect the exhaust tube seals and replace if damaged.
3. Remove the water tube and grommet.
4. Inspect the water tube grommet and replace if damaged.
e f
c d g
b
a
i
55316
a- Oring
b- Oring
c- Flange seal
d- Flange head screw (M6 x 16) (2)
e- Water strainer
f- Seal
g- Exhaust tube
h- Water tube
i- Grommet
5. Inspect the strainer for debris.

6. Inspect the seal.
a - Strainer
a b - Seal
b
55325
90-8M0082471 JULY 2014 Page 5B-17

7. Inspect the water tube and grommet.
b a a - Water tube
b - Grommet
55336
Assembly
1. Ensure that the exhaust tube is clean.
2. Lubricate the Oring with 24C with PTFE. Install the Orings onto the exhaust tube.
3. Install the flange seal onto the exhaust tube as shown.
4. Lubricate the seal with soapy water. Install the seal onto the exhaust tube as shown.
5. Apply Loctite 242 Threadlocker to the threads of the water strainer screws.
6. Install the water strainer. Tighten the screws to the specified torque.
7. Lubricate the grommet with a soap and water solution. Install the grommet into the exhaust tube.
8. Install the water tube into the grommet.
e f
c g
d
b
a
i
55337
a- Oring
b- Oring
c- Flange seal
e- Water strainer
f- Seal
g- Notch
h- Water tube
i- Grommet

66 Loctite 242 Threadlocker Water strainer screw threads 92-809821
Page 5B-18 90-8M0082471 JULY 2014


Flange head screw (M6 x 16) 10 88.5
Assembly
Adapter Plate/Oil Sump
1. Ensure that the two dowel pins are installed in the top of the adapter plate. If they are not, remove them from the
powerhead and install them into the adapter plate.
2. Ensure that the shift shaft bushing, idle relief muffler grommet, adapter plate seal, fuel supply module seal, and cowl drains
are in good condition. Replace if required.
d b
e g
a
55342
a- Adapter plate seal

c- Idle relief muffler grommet
d- Grommet
e- Cowl drain
f- Fuel supply module seal
g- Dowel pin
3. If the two dowel pins are not installed in the bottom of the adapter plate, remove them from the driveshaft housing and
install into the adapter plate. The dowel pins ensure the alignment of the components.
4. Inspect the Orings on the water pump indicator fitting and the water dump fitting. Replace if damaged.
5. Lubricate the Orings and fittings with a soap and water solution.
6. Install the fittings into the adapter plate.
7. Apply Loctite 242 Threadlocker to the flange head screws securing the water pump indicator fitting and the water dump
fitting.
90-8M0082471 JULY 2014 Page 5B-19

b
a
55344
a- Water dump fitting

b- Flange head screw (M6 x 12)
c- Tell tale assembly

66 Loctite 242 Threadlocker Flange head screw (M6 x 16) (M6 x 12) 92-809821

Flange head screw (M6 x 16) 6 53
9. Clean the oil sump and mating surfaces of the adapter plate.
10. Install the oil sump gasket onto the adapter plate.
11. Install the oil sump onto the adapter plate and gasket.
12. Apply Loctite 242 Threadlocker to the ten oil sump screws.
13. Install the screws and tighten in a clockwise sequence to the specified torque.
a- Oil sump
b- Gasket
a c- Dowel pin
b
c
c
55353
Page 5B-20 90-8M0082471 JULY 2014


66 Loctite 242 Threadlocker Flange head screw (M6 x 40) (10) 92-809821

Flange head screw (M6 x 40) (10) 10 88.5
14. Ensure that the upper mount components are installed.
15. Lubricate the exhaust tube seal with a soap and water solution.
16. Install the exhaust tube assembly into the adapter plate. Refer to Exhaust Tube for the assembly procedure.
17. Apply Loctite 242 Threadlocker to the M6 x 25 flange head screw.
18. Secure the exhaust tube with the screw and tighten the screw to the specified torque.
a- Port upper mount

b- Bolt (M12 x 120)
f
c- Snubber washer
d- Washer
e- Exhaust tube
f- Flange head screw (M6 x
a 25)
c d e 55357

66 Loctite 242 Threadlocker Flange head screw (M6 x 25) 92-809821

Flange head screw (M6 x 25) 10 88.5
Driveshaft Housing/Adapter Plate Assembly

1. Lubricate the exhaust tube seal and the water tube grommet with a soap and water solution.
2. Install the exhaust tube seal and water tube grommet into the driveshaft housing.
a - Exhaust tube seal

b - Water tube grommet
a
b
55360
3. Install the adapter plate assembly onto the driveshaft housing.

a. Guide the exhaust tube and water tube into the seal and grommet in the driveshaft housing.
90-8M0082471 JULY 2014 Page 5B-21

b. Align the adapter plate dowel pins with the holes on the driveshaft housing.
a - Adapter plate assembly

b - Dowel pin
c - Driveshaft housing
a
b b
c
55317
4. Apply Loctite 242 Threadlocker to the eight adapter plate mounting screw threads.
5. Install the adapter plate mounting screws. Tighten the bolts in a clockwise sequence to the specified torque.
a
55314
a - Screw (M10 x 60 flange head) (8)

66 Loctite 242 Threadlocker Adapter plate mounting screws (M10 x 60 flange head) (8) 92-809821

Adapter plate mounting bolt (M10 x 60 flange head) (8) 60 44
6. Apply Loctite 242 Threadlocker to the exhaust cooling fitting screw threads.
7. Install the fitting with sprayer hose into the driveshaft housing.
8. Secure the fitting with a flange head screw and washer. Tighten the screw to the specified torque.
9. Install the oil sump grommet into the driveshaft housing.
Page 5B-22 90-8M0082471 JULY 2014

10. Install the oil drain valve into the oil sump. Tighten the oil drain valve to the specified torque.
a- Grommet
b- Oil drain valve
c- Exhaust cooling fitting
d- Flange head screw with washer (M6 x 12)
a
b
c
d
55283

66 Loctite 242 Threadlocker Exhaust tube mounting bolt (M6 x 12 flange head) 92-809821

Oil drain valve 15 133
11. Install one end of the speedometer tube onto the barbed fitting on the driveshaft housing. Push the other end through the
adapter plate gasket and adapter plate.
12. Install the grommet on the fuel supply module (FSM) hose into the adapter plate.
13. Secure the inlet fuel hose to the driveshaft housing with two plastic Jclamps and screws.
14. Route the speedometer hose as shown. Secure it to the exhaust cooling hose and the inlet fuel hose with two plastic clips.
a a- Grommet
b- Inlet fuel hose
c- Adapter plate seal
c d- Speedometer tube
e- Barbed fitting
b f- Plastic clip
d g- Plastic screw and Jclamp
e
55369
90-8M0082471 JULY 2014 Page 5B-23

15. Install the water strainer hoses. Secure the hoses to the water strainer with cable ties.
a - Water strainer FSM water supply hose

b - Water strainer block drain hose
55370
16. Install the fuel supply module onto the driveshaft housing. Refer to Section 3A Fuel Supply Module (FSM).
Page 5B-24 90-8M0082471 JULY 2014

Power Trim
Midsection
Section 5C - Power Trim
Table of Contents
Power Trim Specifications................................................. 5C-2 Testing the Power Trim System with Test Gauge Kit...... 5C-29
Power Trim Assembly Components.................................. 5C-4 Up Pressure Check.................................................. 5C-29
Power Trim Components................................................... 5C-6 Down Pressure Check..............................................5C-31
Power Trim General Information........................................5C-8 Power Tilt Leakage Test Procedure................................ 5C-33
General Information....................................................5C-8 Method 1...................................................................5C-33
Power Trim Operation................................................ 5C-8 Method 2...................................................................5C-33
Trailering Boat/Outboard ........................................... 5C-8 Power Trim System Removal.......................................... 5C-34
Manual Tilting............................................................. 5C-9 Power Trim Disassembly................................................. 5C-36
Purging Power Trim System.......................................5C-9 Draining the Power Trim Fluid.................................. 5C-36
Power Trim Flow Diagrams............................................. 5C-10
TrimUp Circuit......................................................... 5C-10
Trim Cylinder and Shock Piston............................... 5C-37
Memory Piston Removal.......................................... 5C-38 5
C
Tilt Circuit..................................................................5C-12 Power Trim Pump and Motor....................................5C-38
Maximum Tilt............................................................ 5C-13 Manifold Removal and Disassembly........................ 5C-40
TrimDown Circuit.....................................................5C-14 Power Trim Cleaning, Inspection, and Repair................. 5C-41
Shock Function Up................................................... 5C-16 Nonserviceable Components................................... 5C-41
Shock Function Return............................................. 5C-17 Power Trim Assembly......................................................5C-42
Manual Tilt................................................................ 5C-18 ORing Placement.................................................... 5C-42
Trim Limit..................................................................5C-20 Trim Cylinder Rod Installation.................................. 5C-44
Reverse Operation................................................... 5C-21 PressureOperated Check Valve..............................5C-46
Wire Color Code Abbreviations....................................... 5C-21 Down Pressure Relief Valve.....................................5C-46
Troubleshooting............................................................... 5C-21 Tilt Relief Valve.........................................................5C-47
Trim Circuit............................................................... 5C-21 Manifold and Cylinder...............................................5C-47
Hydraulic System Troubleshooting...........................5C-23 Trim Pump and Motor...............................................5C-48
Electrical System Troubleshooting........................... 5C-23 Power Trim System Installation....................................... 5C-49
90-8M0082471 JULY 2014 Page 5C-1

Power Trim

Trim up circuit pressure, minimum 19,300 kPa (2800 psi)
Tilt relief pressure (up) 37206830 kPa (540990 psi)
Trim down circuit pressure 34805860 kPa (505850 psi)
System fluid Power Trim and Steering Fluid or Automatic Transmission Fluid (ATF) (Dexron III)

9 Brass fitting and test adapter threads 92-809822
Sealant
Pivot pin surface and lower pivot pin bore
95 2-4-C with PTFE 92-802859A 1
Upper pivot pin and bore, trim ram bore
Power trim O-rings
114 O-rings 92-858074K01
Fluid
Power trim system
Special Tools

V Hz
H z TEMP
mA
A
mV IG
OFF IP
TEMP
A mA COM V Hz
4516
Adapter Fitting 91822778A 1
91 822778 1 Measures the internal pressure in the up mode for a single cylinder trim system.
12203
Power Trim Test Gauge Kit 9152915A6
Tests circuit pressures for various trim pumps.
3753

Install in place of the manual release valve to measure the internal pressure of
91 822778 2
8637 the power trim pump in the down mode.
Trim Cylinder End Cap Tool 91821709T
Allows easy removal of the trim cylinder end caps. Required if tilt limit spacers
are to be installed or if the trim in limit spacer is to be removed (to allow
additional trim in range).
10691
Page 5C-2 90-8M0082471 JULY 2014

Power Trim
Lockring Pliers SnapOn SRP'4
Aids in the removal of lock rings and the memory piston.
4799
Spanner Wrench 91 74951
Removes and installs trim cylinder end caps.
8775
90-8M0082471 JULY 2014 Page 5C-3

Power Trim
Power Trim Assembly Components

2
55143
Page 5C-4 90-8M0082471 JULY 2014

Power Trim
Power Trim Assembly Components

Torque
1 1 Power trim assembly
2 1 Upper pivot pin
3 2 Trilobe pin
4 1 Anchor pin
90-8M0082471 JULY 2014 Page 5C-5

Power Trim
Power Trim Components
15
13
14 16
13
17
12
13
15
18
9 1
10 4
3
3
7
11 6 5 3
8 3
2
55144
Page 5C-6 90-8M0082471 JULY 2014

Power Trim
Power Trim Components

Torque
1 1 Manifold kit
2 1 Manual release valve kit 4 35
3 1 Valve kit
4 1 Trim limit valve kit
5 2 Oring
6 3 Dowel pin
7 1 Reservoir cap kit 2.5 22
8 2 Screw (0.25020 x 2.250) 15 133
9 1 Cylinder assembly
10 1 Cable assembly
11 1 Screw (M6 x 25) 8 71
12 1 Memory piston assembly
13 2 Oring
14 1 Shock rod kit 61 45
15 1 Screw kit
16 1 Electric motor kit
17 1 Coupler
18 1 Pump assembly
1 Complete Oring kit
90-8M0082471 JULY 2014 Page 5C-7

Power Trim
Power Trim General Information

General Information
The power trim system consists of an electric motor, pressurized fluid reservoir, pump, and trim cylinder.
Trim outboard through entire trim and tilt range several times to remove any air from the system.
The remote control or trim panel is equipped with a switch that is used for trimming the outboard up or down, for tilting the
outboard for shallow water operation at slow speeds, or for trailering. The outboard can be trimmed up or down while engine is
under power or when engine is not running.
Power Trim Operation

With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of
the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an
improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some
potential control hazards.
The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque
results from the outboard being trimmed so the propeller shaft is not parallel to the water surface.
! WARNING
Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss
of boat control. Maintain control of the boat if trimming beyond a neutral steering condition.
Consider the following lists carefully.

1. Trimming in or down can:
Lower the bow.
Result in quicker planing off, especially with a heavy load or a stern heavy boat.
Generally improve the ride in choppy water.
Increase steering torque or pull to the right (with the normal righthand rotation propeller.)
In excess, can lower the bow of some boats to a point where they begin to plow with their bow in the water while on
plane. This can result in an unexpected turn in either direction (called bow steering or oversteering) if any turn is
attempted, or if a significant wave is encountered.
! WARNING
In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by purchasing a stainless
steel tilt pin from your dealer and inserting it in whatever adjustment hole in the transom brackets is desired. The
nonstainless steel shipping bolt should not be used in this application other than on a temporary basis.
2. Trimming out or up can:
Lift the bow higher out of the water.
Generally increase top speed.
Increase clearance over submerged objects or a shallow bottom.
Increase steering torque or pull to the left at a normal installation height (with the normal righthand rotation propeller.)
In excess, can cause boat porpoising (bouncing) or propeller ventilation.
Cause engine overheating if any cooling water intake holes are above the waterline.
Trailering Boat/Outboard
Trailer your boat with the outboard tilted down in a vertical operating position.
Page 5C-8 90-8M0082471 JULY 2014

Power Trim
If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer
to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways, and trailer
bouncing.
21997
IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to maintain proper ground clearance for trailering.
The outboard tilt support lever is not intended to support the outboard for trailering.
Shift the outboard to forward gear. This prevents the propeller from spinning freely.
Manual Tilting
If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.
NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up
during reverse operation.
IMPORTANT: Do not operate the outboard in either the up or down position with the manual tilt valve open. Damage to the
Orings may occur.
Turn out the manual tilt release valve three turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard
to the desired position and tighten the manual tilt release valve.
22362
NOTE: In cold climates, the manual release valve should be opened for storage to prevent pressure buildup in the cylinder due
to thermal expansion.
Purging Power Trim System

IMPORTANT: The fill cap with Oring must be tightened securely before operating the power trim system.
IMPORTANT: Operate the power trim system in short spurts until the hydraulic pump is primed and the trim cylinders move.
Cycle the outboard through the entire trim/tilt range four times.
To check for presence of air in the system, extend cylinders slightly and push down on outboard. If the trim rams retract
more than 3 mm (0.125 in.), air is present. Cycle trim system again and repeat this step.
Check fluid level. Refer to Checking Power Trim Fluid.
90-8M0082471 JULY 2014 Page 5C-9

Power Trim
Power Trim Flow Diagrams

TrimUp Circuit
r
q
d c
p e
o g
f h
n
m
s i
j
54945
Page 5C-10 90-8M0082471 JULY 2014

Power Trim
a- Electric motor k- Upcircuit/tilt pressure relief valve
b- Oil fill cap l- Cylinder
c- Reservoir oil m- Memory piston
d- Oil pump n- Shock piston
e- Downcircuit suction ball o- Impact relief valve
f- Makeup oil check ball and seat p- Shock return valve
g- Upcircuit suction ball q- End cap
h- Downcircuit pressure relief valve r- Trim rod
i- Pressureoperated check valve s- Highpressure oil
j- Manual release valve t- Lowpressure oil
When the trim switch is activated in the up position, the electric motor begins to rotate the pump gears, and the oil pump draws
a small amount of oil through the upcircuit suction port. The oil pump gear rotation forces oil into the passages for the up
circuit. Oil under pressure slides the shuttle spool against the downcircuit pressure operated valve. The shuttle spool
mechanically opens the down pressureoperated valve, allowing oil from the down cavity of the trim cylinder to flow into the oil
pump. This oil returning from the down cavity supplies most of the oil required for the up circuit.
Oil in the up circuit is blocked from returning into the reservoir by the ball inside the downcircuit suction port. The pressure of
the oil forces the upcircuit pressure operated valve to open, allowing the oil to enter the passages inside the manifold leading
to the trim cylinder up cavity. Oil is blocked from all other passages by the closed manualrelease valve. Oil under pressure
enters the trim cylinder below the memory piston. With an increasing amount of oil entering the cylinder, the memory and shock
pistons force the trim rod up and out, raising the outboard engine. Oil on the top of the shock piston exits through a passage
running down along the side of the cylinder and enters the manifold passages. The oil is drawn back into the pump through the
open downpressureoperated valve and enters the pump as supply for the up circuit.
The trim cylinder positions the outboard at the desired trim angle in the 20 maximum trim range. The system will not allow the
outboard to be trimmed above the 20 trim range as long as the engine is above approximately 2000 RPM.
The outboard can be trimmed above the 20 maximum trim angle for shallow water operation by keeping the engine RPM
below 2000. If the RPM increases over 2000, and the propeller is deep enough, propeller thrust causes the trim system to
return the outboard to the 20 maximum trim position. Refer to Trim Limit, following.
90-8M0082471 JULY 2014 Page 5C-11

Power Trim
Tilt Circuit
a- Electric motor
b- Oil fill cap
c- Reservoir oil
r d- Oil pump
e- Downcircuit suction
q ball
f- Makeup oil check ball
and seat
a
g- Upcircuit suction ball
h- Downcircuit pressure
relief valve
i- Pressureoperated
check valve
j- Manual release valve
o
k- Upcircuit/tilt pressure
relief valve
t l- Cylinder
m- Memory piston
l n- Shock piston
o- Impact relief valve
p- Shock return valve
d c q- End cap
p r- Trim rod
o s- Highpressure oil
b
t- Lowpressure oil
u- Pressure relief
n passage
m e
g
u h
f
s i
j
Tilt
54945
In the up mode, as the trim rod extends from the cylinder, the memory piston clears or uncovers the pressure relief passage.
Oil from the up cavity enters this passage and, if required, causes the tilt relief plunger to open the tilt pressure relief valve. This
valve lowers the amount of pressure available to lift the outboard motor. With the engine in forward gear, and at high RPM, the
oil pressure available cannot overcome the force of the propeller thrust, limiting the trim range to below the pressure relief
passage. Up pressure flows into the trim relief passage and returns back into the reservoir. When the engine's RPMs fall, or if
the engine is not in forward gear, oil pressure is available to extend the trim rod up into the tilt range.
Page 5C-12 90-8M0082471 JULY 2014

Power Trim
Maximum Tilt
a- Electric motor
b- Oil fill cap
c- Reservoir oil
r d- Oil pump
q ball
f- Makeup oil check
ball and seat
a
p g- Upcircuit suction ball
o h- Downcircuit pressure
relief valve
i- Pressureoperated
n check valve
mo
relief valve
t l- Cylinder
m- Memory piston
l n- Shock piston
d c q- End cap
r- Trim rod
b s- Highpressure oil
t- Lowpressure oil
s
e
g
f h
i
j
54939
With the trim rod fully extended at the maximum tilt position, the pressure inside of the trim cylinder increases to the pressure
setting of the tilt relief valve. Pressure forces the tilt relief plunger to move and unseat the tilt relief valve allowing highpressure
oil to return to the reservoir through passages in the manifold. Oil flow continues until the up button is released.
90-8M0082471 JULY 2014 Page 5C-13

Power Trim
TrimDown Circuit
r
q
d c
e
g
o p h
f
n
m i
s j
54943
Page 5C-14 90-8M0082471 JULY 2014

Power Trim
a- Electric motor k- Upcircuit/tilt pressure relief valve
b- Oil fill cap l- Cylinder
c- Reservoir oil m- Memory piston
d- Oil pump n- Shock piston
e- Downcircuit suction ball o- Impact relief valve
f- Makeup oil check ball and seat p- Shock return valve
g- Upcircuit suction ball q- End cap
h- Downcircuit pressure relief valve r- Trim rod
i- Pressure operated check valve s- Lowpressure oil
j- Manual release valve t- Highpressure oil
When the trim switch is activated in the down position, the electric motor reverses direction. With the oil pump gears rotating
opposite of trim up, the flow of oil is reversed. Oil is drawn through the downcircuit suction port, and into the oil pump gears.
The pump forces pressurized oil into the down passages. Oil slides the shuttle spool into the upcircuit pressure operated valve.
The shuttle spool mechanically opens the upcircuit pressure operated valve and allows oil from the up cavity of the trim
cylinder to return into the oil pump. This oil, returning from the up cavity, supplies the oil required for the down circuit. The oil is
blocked from returning into the reservoir by the ball inside the upcircuit suction port. Oil, under pressure, opens the
downcircuit pressure operated valve and enters the down passages inside of the manifold.
The manifold passage connects into the trim cylinder passage leading to the top of the cylinder. The cavity inside the cylinder
above the shock piston is the down cavity. As the down cavity fills with oil, the trim rod retracts into the cylinder, lowering the
outboard motor. Oil from the up cavity exits the cylinder and is drawn back into the pump through the open upcircuit pressure
operated valve. When the trim rod reaches full travel, the oil pressure inside the down circuit rises until the downcircuit
pressure relief valve opens, bypassing oil back into the reservoir. When the trim button is released, the pump stops supplying
oil, both of the pressureoperated valves close and, if open, the downcircuit pressure relief valve closes. The closed valves
lock the fluid on either side of the shock piston and memory piston, holding the outboard motor in position.
90-8M0082471 JULY 2014 Page 5C-15

Power Trim
Shock Function Up
a- Electric motor
b- Oil fill cap
c- Reservoir oil
r d- Oil pump
q ball
and seat
a
relief valve
i- Pressureoperated
check valve
o
relief valve
t l- Cylinder
p m- Memory piston
o
n- Shock piston
n p- Shock return valve
d c q- End cap
r- Trim rod
l b s- Up cavity
t- Highpressure oil in
the down cavity
m e
g
f h
s i
j
54941
Oil inside the down cavity is locked in a static position by the closed downcircuit pressureoperated valve, the manual release
valve, and the manifold reverse suction valve. If the outboard strikes an underwater object while in forward gear, the trim rod
tries to rapidly extend from the cylinder, increasing the pressure inside the trim cylinder down cavity and connecting passages.
When the pressure increases to the relief valve setting, the impact relief valves located inside the shock piston open and allow
the fluid to pass through the shock piston. As the fluid passes through the piston, the trim rod extends from the trim cylinder.
The memory piston remains held in position by vacuum created by the oil in the up cavity being locked in a static position.
Page 5C-16 90-8M0082471 JULY 2014

Power Trim
Shock Function Return
a- Electric motor
b- Oil fill cap
c- Reservoir oil
r d- Oil pump
q ball
and seat
a
relief valve
i- Pressure operated
check valve
o
relief valve
t l- Cylinder
p
m- Memory piston
o
n- Shock piston
n p- Shock return valve
d c q- End cap
r- Trim rod
l b s- Up cavity
t- Down cavity
u u- Oil between shock and
memory pistons
m e
g
f h
s i
j
54940
After the engine clears the underwater object, the weight of the engine increases the oil pressure between the memory piston
and shock piston to the level required to open the shock return valve inside the shock piston. This allows the oil to bleed back
through the shock piston into the down cavity. If required, additional oil enters the down cavity through the manifold
reversesuction valve. This returns the engine back against the memory piston and into the original running position.
90-8M0082471 JULY 2014 Page 5C-17

Power Trim
Manual Tilt
a- Electric motor
b- Oil fill cap
c- Reservoir oil
r d- Oil pump
q ball
and seat
a
relief valve
i- Pressureoperated
check valve
relief valve
t l- Cylinder
m- Memory piston
l n- Shock piston
d c q- End cap
p r- Trim rod
o s- Up cavity
b
t- Down cavity
n
m e
g
u h
f
s i
j
54938
To manually tilt the outboard engine, back out the manual release valve 34 turns. With the valve backed out, the internal
passages inside the manifold are connected. These passages connect both the cylinder down and up cavities, along with the
reservoir, allowing the engine to be raised or lowered. Trim rod movement continues until the manual release valve is closed,
locking the fluid inside of the cylinder and manifold. If the outboard motor is to be raised manually, turn the manual release
valve counterclockwise to the full out position. When in the full out position, oil in the trim cylinder can flow freely from the up
side to the down side, or from the down side to the up side. The oil return line into the reservoir is also open, allowing free oil
flow to either side of the tilt cylinder to accommodate the differential oil capacities between the tilt cylinder up side and down
side cavities.
Page 5C-18 90-8M0082471 JULY 2014

Power Trim
When trimming the outboard in either the up or down position, with the manual tilt valve open or leaking, little or no movement
occurs. Oil pressure from the pump moves to both the up cavity, and through the manual tilt valve into the down cavity. There is
equal pressure in each cavity, resulting in little or no movement.
IMPORTANT: Do not operate the outboard or trim the outboard in either the up or down direction with the manual tilt valve
open. Damage to the Orings may occur. Close the manual release valve before operating the trim or the outboard.
90-8M0082471 JULY 2014 Page 5C-19

Power Trim
Trim Limit
r
q
d c
p
o
b
n
m e
g
u
f h
s i
j
54944
Page 5C-20 90-8M0082471 JULY 2014

Power Trim
a- Electric motor l- Cylinder
b- Oil fill cap m- Memory piston
c- Reservoir oil n- Shock piston
d- Oil pump o- Impact relief valve
e- Downcircuit suction ball p- Shock return valve
f- Makeup oil check ball and seat q- End cap
g- Upcircuit suction ball r- Trim rod
h- Downcircuit pressure relief valve s- Highpressure oil
i- Pressureoperated check valve t- Lowpressure oil
j- Manual release valve u- Pressure relief passage
k- Upcircuit/tilt pressure relief valve
When the weight of the outboard and propeller thrust reach sufficient levels, the pressure inside the trim cylinder increases to
the pressure required to move the tilt relief piston. The tilt relief plunger opens the tilt relief valve. Up pressure oil flows into the
trim relief passage, and returns back into the reservoir. If the outboard engine is positioned in the tilt range (beyond full trim
position) when the tilt relief valve opens, it will move back down to the full trim position (trim limit).
Reverse Operation
To prevent the outboard from coming up or trailing out, when shifted into reverse and/or throttling back rapidly, oil in the trim
system must be locked in a static position. This is accomplished with the up and down pressure operated valves. When the
pump is not operating, the shuttle valve is in a centered position and the pressure operated valves are held closed by the
springs behind the valve poppet. Oil is now locked in both ends of the cylinder preventing the trim rod from moving in or out.

BLK Black BLU Blue
BRN Brown GRY Gray
RED Red TAN Tan
Troubleshooting
Trim Circuit
When the relays are deenergized, contacts 30 and 87a complete the circuit to the trim motor leads. Both motor leads are
connected to ground.
90-8M0082471 JULY 2014 Page 5C-21

Power Trim
When contact 85 is energized from the trim switch, the up relay is energized. Contacts 30 and 87 close, completing the circuit
to 12 V (+) to the blue trim motor lead. The trim down relay remains deenergized. The trim motor tilts the engine up.
d (+) BLK
Trim up circuit
LT BLU/WHT
a - Trim relay contacts
a
RED (+) e b - Trim up relay
87 85 87a 87 c - Trim down relay
87a b d - To trim up switch
86 85 e - 12 V (+)
86 30 f - To trim motor (+)
30
h g - To trim motor ()
BLU
BLK/WHT
(+) f h - To ECM
GRN/WHT
RED (+)
85 87a 87
c
86 30
GRN
() g 55473
Support the outboard with a tilt lock pin when servicing the power trim system.
IMPORTANT: After debris or failed components have been found, it is recommended that unit be disassembled completely and
all Orings be replaced. Check valve components and castings must be cleaned using engine cleaner and compressed air, or
replaced prior to reassembly.
IMPORTANT: Power trim system is pressurized. Outboard must be in the full up position (trim rod fully extended) prior to fill/
drain plug or manual release valve removal.
1. Refer to instructions following if disassembly is required when servicing.
2. Follow preliminary checks before proceeding to troubleshooting flow diagrams following.
Preliminary Checks
IMPORTANT: Operate power trim system after each check to see if problem has been corrected. If the problem has not been
corrected, proceed to next check.
1. Ensure manual release valve is tightened to full clockwise position.
2. Check trim pump fluid level with outboard in full up position and fill if necessary. Refer to Bleeding Power Trim Unit in this
section.
3. Check for external leaks in power trim system. Replace defective parts if leak is found.
4. Outboard not holding tilted position (falls down to trim position) indicates debris or defective components in trim assembly.
Clean or replace components as required.
Page 5C-22 90-8M0082471 JULY 2014

Power Trim
Hydraulic System Troubleshooting

Condition/Problem
Condition of Trim System Primary Cause Secondary Cause
Trim motor runs; trim system does not move up or down 1,5 2, 4, 6, 9
Does not trim full down. Up trim OK. 3 2, 4, 6
Does not trim full up. Down trim OK. 1 2, 4, 6
Partial or jerky down/up 1 10
Does not trim under load 5 2, 7, 8, 11
Does not hold trim position under load 5 2, 4, 6
Trail out when backing off from high speed 3 4, 5, 10
Leaks down and does not hold trim 5, 11 2, 4, 6
Trim motor working hard and trims slowly up and down 7 1, 8
Trims up slowly 12 1, 2, 11
Starts to trim up from full down position when the down trim button is pressed 3 4
Trim position will not hold in reverse 3 4, 5, 6, 12
Problem/Solution
No. Problem Solution
1. Low fluid level Add Power Trim and Steering Fluid or ATF (Type Dexron III).
Pressure test the pump. Refer to Testing the Power Trim System
2. Defective hydraulic pump
with Test Gauge Kit.
3. Trim cylinder shock piston ball not seated Inspect the ball seat for nicks or contamination.
Trim cylinder piston or memory piston Orings
4. Inspect the Orings for cuts or abrasion.
leaking or cut
Manual release valve is leaking (check condition
5. Ensure that the valve is fully closed. Inspect Orings.
of Orings) (valve not fully closed)
6. Debris in system Inspect for debris. Refill the system with clean fluid.
7. Battery low Check battery.
8. Electric motor defective Refer to Electrical System Troubleshooting.
9. Broken motor/pump driveshaft Inspect for damage.
10. Air pocket under pump Purge air from the system. Refer to Purging Power Trim System.
11. Defective up/tilt pressure relief valve Replace the up/tilt pressure relief valve assembly.
12. Defective downpressure relief valve Replace the downpressure relief valve assembly.
Electrical System Troubleshooting

General Checks
Before troubleshooting the power trim electrical system, check for the following:
Disconnected wires
Loose or corroded connections
Fully engaged plugin connections
Low battery charge
Condition/Problem
Condition of Trim System Problem No.
The trim motor does not run when the trim button is pressed 1, 2, 4, 5, 6, 7
90-8M0082471 JULY 2014 Page 5C-23

Power Trim
Condition of Trim System Problem No.

The trim system trims opposite of the buttons 3
The cowl mounted trim buttons do not activate the trim system 2, 4, 5, 6
Problem/Solution
No. Problem Solution
1. Battery is low or discharged Check the battery.
2. Open circuit in the trim wiring Check for an open connection.
Wiring is reversed in the remote control, cowl switch, or
3. Verify all the connections.
trim leads
4. Wire harness is corroded through Replace the wiring harness.
5. Internal motor problem (brushes, shorted armature) Check for an open connection. Replace the motor.
6. Trim switch failure Replace the switch.
Verify that all relays are functioning correctly. Check the
7. Relay not operating
voltage at the trim bullets.
Power Trim Relay Test Procedure

NOTE: To remove the power trim relays, insert a flatblade screwdriver into the relay lock tab. Gently twist the blade and pry
the relay connector loose. Pull the relay connector out. Do not pull on the wires.
d c
b
e
f
55470
a- Lock tab
b- Down relay
c- Up relay
d- Start relay
e- Main power relay
f- Positive (+) 12volt power stud
g- Negative () 12volt ground
The trim motor relay system, used on permanent magnet trim systems, connects each of the two wires from the trim motor to
either a ground or positive lead to allow the motor to run in both directions.
If the motor will not run in the up direction, it may be either the up relay is not making contact to 12 volts or the down relay is not
making contact to ground. The opposite is true if the system will not run down. When the system is not energized, both relays
should connect the heavy motor leads to ground.
To test which relay is faulty if the trim system does not operate in one direction:
1. Disconnect the heavy gauge pump wires from the trim control relay.
2. Check for continuity between the heavy leads from the trim relays to ground.
Page 5C-24 90-8M0082471 JULY 2014

Power Trim
Meter Test Leads Meter Scale Reading ()

Red Black
Green Ground Full continuity x 1) < 20
Blue Ground Full continuity x 1) < 20
3. Replace the relay that does not have continuity.
4. Connect a voltmeter to the heavy blue lead and to ground. There should be 12 volts on the blue lead when the up switch is
pushed and 12 volts on the green lead when the down switch is pushed. Replace the relay that does not switch the lead to
positive.
Meter Test Leads Meter Scale Test Condition Reading (VDC)

Red Black
Blue Ground DC volts Up switch pushed 12 volts
Green Ground DC volts Down switch pushed 12 volts
Power Trim Relay Removal

2. Remove the flywheel. Refer to Section 2B Flywheel Removal.
4. Use a small, flatblade screwdriver to press the relay mounting tab and pull the relay up to remove it from the electrical
plate.
d a- Relay
b- Mounting base tab
c- Electrical plate
d- Tab location
c b a
55468
5. Inspect the engine harness relay connector for damaged spade terminals or loose wires.
6. To install the flywheel. Refer to Section 2B Flywheel Installation.
90-8M0082471 JULY 2014 Page 5C-25

Power Trim
Power Trim Electrical Circuit
e
b c d
l
m
3
9
T8
2 f
6 g
S110
S106
S121
GRY
h
a
S109
5 S109 1
4 8
BRN/WHT
T6 7
i
k n
55474
j
a- ECM
b- Main power relay
c- Down relay
d- Up relay
e- Remote control
f- Trim motor down lead
g- Trim motor up lead
h- 14pin connector
i- Fuse holder
j- Cowl tilt switch
k- Trim position sensor
l- Positive (+)12volt power (hot stud)
m- Negative () 12volt ground
n- Power trim 15amp fuse (EF)
Troubleshooting the Down Circuit

NOTE: Refer to the preceding wiring diagrams for connection points when troubleshooting the electrical systems. Connection
points are specified by number.
Page 5C-26 90-8M0082471 JULY 2014

Power Trim
Step Test Procedure Test Result

Battery voltage measured:
Disconnect the down relay and 2pin relay Reconnect the down trim relay.
Step 1: Check for
connector. Connect the voltmeter red lead
battery voltage at
to point 1 and black lead to ground. Press Go to step 2.
point 1. No battery voltage measured:
the cowl down tilt switch.
Go to step 3.
Go to step 5.
Step 2: Check for No battery voltage measured:
Connect the voltmeter red lead to point 3
battery voltage at There is an open circuit between point 3 and the
and the black lead to ground.
point 3. positive (+) battery terminal.
Check for loose or corroded connections.
Check the wires for an open circuit.
Disconnect the 3pin cowl switch A wire is open between points 4 and 1.
Step 3: Check for
connector. Connect the voltmeter red lead No battery voltage measured:
battery voltage at
to point 4 and the black lead to ground.
point 4. Reconnect the 3pin connector.
Press the trim down switch.
Go to step 4.
The trim switch is faulty.
battery voltage at
and the black lead to ground. Check for a loose or corroded wire at point 5.
point 5.
There is an open circuit in the wire supplying current
to point 5.
Reconnect the 2pin relay connector. Battery voltage measured:
Step 5: Check for Connect the voltmeter red lead to point 2
Go to step 6.
battery voltage at (female bullet connector) and the black
No battery voltage measured:
point 2. lead to ground. Press the down trim
button. The relay is defective. Replace the relay.
Relay is good:
The pump motor wiring is defective.
Step 6: Check Up Test the up relay. Refer to Power Trim
relay. Relay Test preceding. The pump motor is defective.
Relay is faulty:
Replace the relay.
Troubleshooting the Up Circuit

NOTE: Refer to the preceding wiring diagrams for connection points when troubleshooting the electrical systems. Connection
points are specified by number.

Disconnect the up relay and the 2pin Reconnect the up trim relay.
Step 1: Check for
relay connector. Connect the voltmeter
battery voltage at Go to step 2.
red lead to point 8 and the black lead to
point 8. No battery voltage measured:
ground. Press the cowl up tilt switch.
Go to step 3.
90-8M0082471 JULY 2014 Page 5C-27

Power Trim

Go to step 5.
battery voltage at There is an open circuit between point 3 and the
and the black lead to ground.
point 3. positive (+) battery terminal.
Check for loose or corroded connections.
Check wires for an open circuit.
Disconnect the 3pin cowl switch A wire is open between points 7 and 8.
Step 3: Check for
connector. Connect the voltmeter red lead No battery voltage measured:
battery voltage at
to point 7 and the black lead to ground.
point 7. Reconnect the 3pin connector.
Press the trim up switch.
Go to step 4.
The trim switch is faulty.
battery voltage at
and the black lead to ground. Check for a loose or corroded wire at point 5.
point 5.
There is an open circuit in the wire supplying current
to point 5.
Reconnect the 2pin relay connector. Battery voltage measured:

Step 5: Check for
Connect the voltmeter red lead to point 6 Go to step 6.
battery voltage at
and the black lead to ground. Press the No battery voltage measured:
point 6.
up trim button. The relay is defective. Replace the relay.
Relay is good:
The pump motor wiring is defective.
Step 6: Check down Test the down relay. Refer to Power Trim
relay. Relay Test preceding. The pump motor is defective.
Relay is faulty:
Replace the relay.
Troubleshooting the Up and Down Circuits (All Circuits Inoperative)

NOTE: Refer to the previous wiring diagram for the location of wire connections.
Problem Possible Cause Remedy
The up and down trim switches are both 1. Faulty trim switch. 1. Replace the trim switch.
inoperative, but the cowl switch does 2. A wire is open between the
operate. 2. Check for a loose or corroded connection.
fuse holder and the trim switch.
1. Replace the fuse. Locate the cause of the
1. The 15amp fuse blown. blown fuse. Check electrical wiring for a shorted
circuit.
2. One of the trim pump motor
2. Check the wire connections at point 2 or 6 for
wires is open between the motor
loose or corroded condition.
and the relays.
Trim switch and cowl switch are both 3. If voltage is present at the connections at point
inoperative. 2 or 6 when the appropriate trim button is
3. Faulty trim pump motor.
pressed, then the motor is faulty. Replace the
motor.
4. Check the trim relays. Refer to Power Trim
4. Faulty trim relay.
Relay Test.
5. A wire is open between the
5. Check for an open connection or a cut wire.
fuse holder and the solenoid.
Trim system operates (motor runs) 1. The trim or cowl switch is
1. Replace the trim switch.
without pressing the switches. shorted.
Page 5C-28 90-8M0082471 JULY 2014

Power Trim
Testing the Power Trim System with Test Gauge Kit

Up Pressure Check
IMPORTANT: This test will not locate problems in the trim system. The test will measure system pressure. If minimum
pressures are not obtainable, the trim system requires additional repair.
IMPORTANT: Ensure the battery is fully charged (12v minimum) before performing the following tests.
1. Tilt the outboard to the full up position and engage the tilt lock lever.
2. Slowly remove the fill plug to bleed pressure from the reservoir.
3. Remove the circlip securing the manual release valve and unscrew the release valve from the trim assembly.
NOTE: A small amount of trim fluid may drip from the manual release valve hole. Place a suitable container under the trim
assembly to collect any leakage.
NOTE: Assemble the test adapter by using the Oring installation tool to position the small Oring onto adapter, then install
the medium Oring and lastly the large Oring. Thread the brass fitting into the test adapter securely using Loctite 567 PST
Pipe Sealant on threads.
91 822778 1 a- Brass fitting

b- Test adapter
c- Large Oring
d- Medium Oring
a b c d e f 7095
e- Small Oring
f- Oring installation tool

Sealant
4. Install the test adapter into the manual release valve hole.
a - Test adapter
7098
90-8M0082471 JULY 2014 Page 5C-29

Power Trim
5. Thread the hose from the test gauge kit into the brass fitting on the adapter.
e a- Brass fitting
b- Test gauge assembly
c- Tilt pin
d- Hose
a d e- Hose (not used)
c
b
7099

6. Reinstall the fill plug.
7. Remove the tilt stop pin from the transom brackets.
8. Run the trim up and disengage the tilt lock lever.
IMPORTANT: Install the tilt pin correctly to prevent transom failure and personal injury.
9. Move the outboard in until the hole in the swivel bracket ear aligns with the 4th tilt hole in the transom bracket. Lock the
engine in the trim range by installing a 10 mm (3/8 in.) diameter tilt pin, or two 10 mm (3/8 in.) hardened bolts and nuts
through the transom brackets and swivel bracket in the hole shown.
a - 4th tilt pin hole
a
22365
Page 5C-30 90-8M0082471 JULY 2014

Power Trim
10. Open valve "a" and close valve "b".
a b
7101
11. Run the trim up to the full up position. Record the pressure reading on gauge. Release the trim switch.
Power Trim
Up pressure (minimum) 19,300 kPa (2800 psi)
12. Run the trim down to release pressure.
13. Remove the spare tilt pin or bolts and nuts.
14. Tilt the outboard full up and engage the tilt lock lever.
15. Slowly remove the fill plug to bleed trapped pressure.
16. Remove the test gauge hose and test adapter.
17. Reinstall the manual release valve and secure the valve with a circlip.
18. Retighten the fill plug.
NOTE: If pressure is out of specified pressure range, troubleshoot system per instructions preceding in this section.
Down Pressure Check

IMPORTANT: This test will not locate problems in the trim system. The test will measure system pressure. If minimum
pressures are not obtainable, the trim system requires additional repair.
IMPORTANT: Ensure that the battery is fully charged (12 V minimum) before performing the following tests.
1. Tilt the outboard to the full up position, and engage the tilt lock lever.
2. Slowly remove the fill plug to bleed pressure from the reservoir.
3. Remove the circlip securing the manual release valve, and unscrew the release valve from the trim assembly.
NOTE: A small amount of trim fluid may drip from the manual release valve hole. Place a suitable container under trim
assembly to collect any leakage.
NOTE: Assemble the test adapter by using the Oring installation tool to position the small Oring onto adapter, then the
medium Oring, and lastly the large Oring. Thread the brass fitting into the test adapter securely using Loctite 567 PST
Pipe Sealant on threads.
91 822778 2 91-82278A2
a - Brass fitting
b - Test adapter
c - Large Oring (install last)
a b c d e f 15818
d - Medium Oring (install second)
e - Small Oring (install first)
f - Oring installation tool

Sealant
90-8M0082471 JULY 2014 Page 5C-31

Power Trim
4. Install the test adapter into the manual release valve hole.
a - Test adapter
7098

5. Thread the hose from the test gauge kit into the brass fitting on the adapter.
e a- Brass fitting
b- Test gauge assembly
c- Tilt pin
d- Hose
a d e- Hose (not used)
c
b
7099

6. Reinstall the fill plug.
7. Run the trim up.
8. Disengage the tilt lock lever.
Page 5C-32 90-8M0082471 JULY 2014

Power Trim
9. Open valve "a" and close valve "b."
a b
7101
10. Run the trim to the full down position. Record the pressure reading on the gauge. Release the trim switch.
Power Trim
Down pressure 34805860 kPa (505850 psi)
11. Tilt the outboard full up and engage the tilt lock lever.
12. Slowly remove the fill plug to bleed trapped pressure.
13. Remove the test gauge hose and adapter.
14. Reinstall the manual release valve and secure the valve with a circlip.
15. Retighten the fill plug.
NOTE: If the pressure is out of specified pressure range, troubleshoot system per instructions in this section.
Power Tilt Leakage Test Procedure

Method 1
1. Extend the power tilt cylinder to the full up position.
2. Measure the distance between the cylinder cap and the bottom of the power tilt cylinder rod eye.
3. Wait 24 hours and measure the distance again.
a- Cylinder rod
b- Rod eye
c- Cylinder cap
d- Measured distance
b
d
a
c
36840
Power Tilt System Leakage Specification

Cylinder rod leakdown in 24 hour period Less than 55 mm (2.2 in.)
Method 2
1. Extend the power tilt cylinder to the full up position.
2. Mark the tilt cylinder rod 55 mm (2.2 in.) above the cylinder cap with an indelible marker.
90-8M0082471 JULY 2014 Page 5C-33

Power Trim
3. Wait 24 hours.
4. If the marked line is visible, the power tilt unit is within specifications for leakage.
Power Tilt System Leakage Specification

Cylinder rod leakdown in 24 hour period Less than 55 mm (2.2 in.)
Power Trim System Removal

1. Tilt the outboard to the full up position and support it with the tilt lock lever.
a - Tilt lock knob

b - Tilt lock lever
a
55174
2. Remove the Jclip securing the trim position sensor and power trim motor harnesses.
3. Remove the two screws securing the trim position sensor. Remove the trim position sensor.
a- Trim sensor
harnesses
d
b
c
55175
Page 5C-34 90-8M0082471 JULY 2014

Power Trim
4. Remove the trilobe pin from the power trim cylinder rod eye.
a - Trilobe pin
b - Rod eye
55176
5. Use a suitable drift punch to drive out the rod eye pin. Retract the power trim cylinder rod.
6. Inspect the upper pivot pin bearings.
NOTE: Do not remove the bearings unless replacement is required.
If the bearings require replacement:
a. Remove the bearings using a drift punch.
b. Install the bearings flush with the inside wall of the swivel bracket.
a - Upper pivot pin bearings

b
55177
7. Remove the screw securing the ground cable.

8. Use a suitable drift punch to remove the lower trilobe pin.
a- Anode
b- Screw (M6 x 25) and washer
c- Ground cable
d- Lower trilobe pin
c
a
b 55480
90-8M0082471 JULY 2014 Page 5C-35

Power Trim
9. Use a suitable drift punch to drive out the lower pivot pin through the power trim assembly and the anchor bracket.
a - Lower pivot pin

b - Anchor bracket
c - Power trim assembly
a b c
55482
! WARNING
Damaged wires can cause electrical problems, resulting in system failure. In some cases, this can affect boat operation,
leading to personal injury. Use conduit, hose clamps, grommets, or other appropriate measures to protect all electrical wires.
Do not overtighten clamps and keep harnesses away from heat sources during installation.
10. Pull the power trim harness through the starboard clamp bracket.
11. Tilt the power trim cylinder rod out first from the swivel bracket and remove the power trim assembly.
Power Trim Disassembly

Draining the Power Trim Fluid
IMPORTANT: The power trim system is pressurized. The trim cylinder rod must be fully extended in the up position prior to
removing the reservoir plug or manual release valve.
1. Extend the trim cylinder rod to the full up position.
2. Remove reservoir plug.
3. Remove manual release valve assembly.
4. Drain the fluid into a clean container.
5. Inspect the fluid for contamination.
a - Reservoir plug
b - Manual release valve
b
55517
Page 5C-36 90-8M0082471 JULY 2014

Power Trim
Trim Cylinder and Shock Piston

IMPORTANT: The power trim system is pressurized. The trim cylinder rod must be fully extended in the up position prior to
removing the reservoir plug or manual release valve.
1. Remove the power trim unit from the outboard. Refer to Power Trim System Removal.
2. Extend the trim cylinder rod to the full up position.
3. Drain the fluid. Refer to Draining the Power Trim Fluid.
4. Remove the trim cylinder end cap.
a - Trim cylinder rod

b - Trim cylinder end cap
55546

5. Drain any remaining fluid from the cylinder.
6. Remove the trim cylinder rod.
7. Inspect the shock piston for debris in any of the seven impact relief valves and the shock return valve.
IMPORTANT: If debris is found in any of the valves, the piston is likely leaking and does not hold trim position. The shock
piston is not serviceable. Replace the shock piston/rod/end cap assembly.
b a - Impact relief valve (7)

b - Shock return valve
48791
90-8M0082471 JULY 2014 Page 5C-37

Power Trim
Memory Piston Removal

1. Use lockring pliers or a suitable tool to remove the memory piston from the cylinder.
a - Lockring pliers
7127
Lockring Pliers SnapOn SRP'4

2. Remove the Oring from the memory piston.
a - Memory piston
b - Oring
a
b
48711
Power Trim Pump and Motor

NOTE: The pump is not serviceable and is replaced as a complete assembly.
1. Remove the power trim unit from the outboard. Refer to Power Trim System Removal.
2. Drain the fluid from the reservoir into a clean container. Refer to Draining the Power Trim Fluid.
3. Secure the power trim unit in a softjawed vice.
4. Remove the two bolts securing the electric motor and remove the motor.
a - Motor
b - Screw (M6 x 35)
b
b
55518
5. Remove the coupler.
Page 5C-38 90-8M0082471 JULY 2014

Power Trim
6. Remove the two bolts securing the pump to the base.
a a - Pump
b b - Screw (1032 x 0.625)
c - Coupler
55521
7. Clean the reservoir and the oil passages in the reservoir.

8. Remove the make up oil check seat and check ball.
9. Inspect the make up oil check seat and replace the Orings.
NOTE: The internal pump components are not serviceable.
a b a - Make up oil check seat, Oring, and check ball

c
b - Dowel bushing
c - Pump Orings
55524
10. Inspect the motor Oring and drive tang.
a - Oring
b - Drive tang
55525
Trim Motor Electrical Tests

Connect a 12volt supply to the motor leads. If the motor fails to run, replace the motor assembly.
90-8M0082471 JULY 2014 Page 5C-39

Power Trim
NOTE: The trim motor is not serviceable and is replaced as an assembly.
Manifold Removal and Disassembly

1. Remove two screws to remove manifold from cylinder.
a - Screw (0.250 20 x 2.25) (2)
a 55522
2. Remove the tilt relief assembly, Orings, and dowel pins. Place the components into a clean plastic bag.
Tilt relief assembly

a - Tilt relief assembly
b - Spring
c - Poppet
d - Spool housing
e - Plunger
f - Oring (2)
g - Dowel pin (3)
g
f
d
e
a
b
c
55520
3. Remove the down relief valve components.
Down relief valve components

a - Spring
b - Spring guide/seat
c - Ball
d - Plug
a
b c d
55523
Page 5C-40 90-8M0082471 JULY 2014

Power Trim
4. Remove the pressure operated check valve components. Insert a 3/32 in. drift pin through the orifice in the check seat to
remove the opposite seat and the spool. Place the components in a clean plastic bag.
e Pressure-operated check valve

c d components
b a - Spool
b - Seat
c - Poppet
a d - Spring
c b e - Plug
d
e
55519
Power Trim Cleaning, Inspection, and Repair

IMPORTANT: Components must be dirt and lint free. The slightest amount of debris in the power trim system could cause the
system to malfunction.
1. Inspect the fluid for contamination.
2. Clean all components with parts cleaner and dry with compressed air.
NOTE: It is recommended that all Orings in the trim system be replaced. Use Oring kit 8M0089947.
3. Inspect the power trim body for contamination.
4. Inspect the individual valve components for contamination and damage.
5. Clean the internal passages with parts cleaner and dry with compressed air.
6. Install new Orings when installing the components.
7. Lubricate all Orings with Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid
(ATF).

114 Power trim O-rings 92-858074K01
Fluid
Nonserviceable Components
The end cap, cylinder rod, and shock piston are not serviceable except for the Orings. They must be replaced as a
complete assembly.
The hydraulic pump is not serviceable except for the Orings.
The electric motor is not serviceable.
90-8M0082471 JULY 2014 Page 5C-41

Power Trim
Power Trim Assembly

ORing Placement
13
3
9 12
5 8
10
11
4
2
2 8
10
5 7
11 8
55254
Page 5C-42 90-8M0082471 JULY 2014

Power Trim
Ref. Qty. Description

1 1 Cylinder end cap Oring
2 2 Cylinder to manifold joint Oring
3 1 Shock piston Oring
3 1 Memory piston Oring
4 1 Down relief valve plug Oring
5 2 Manual release valve and tilt relief valve plunger Oring
6 2 Pumptomanifold Oring
7 1 Manual release valve Oring
8 3 Manual release valve, makeup check valve, and pressureoperated check spool Oring
9 3 Tilt relief valve body Oring
10 2 Pressureoperated check seat Oring
11 2 Pressureoperated check cap Oring
12 1 Reservoir plug Oring
13 1 Motortomanifold Oring
! CAUTION
Contamination can damage the hydraulic system or cause the system to malfunction. Failure of power trim or steering
components can result in injury or product damage. Ensure that the work area, shop tools and all components are clean and
lint free during reassembly.

114 O-rings 92-858074K01
Fluid
c
a - Inside diameter (I.D.)
b - Outside diameter (O.D.)
c - Width
b a
55268
90-8M0082471 JULY 2014 Page 5C-43

Power Trim
2 4 5 6 7
13
9 10 11 12
8
55547
Oring Dimensions
Ref Description ORing I.D. ORing O.D. ORing Width
1 Cylinder end cap Oring 47.34 mm (1.860 in.) 50.90 mm (2.000 in.) 1.78 mm (0.070 in.)
2 Cylindertomanifold joint Oring 5.28 mm (0.208 in.) 8.84 mm (0.348 in.) 1.78 mm (0.070 in.)
3 Shock piston Oring 40.64 mm (1.600 in.) 51.31 mm (2.020 in.) 5.33 mm (0.210 in.)
3 Memory piston Oring 40.64 mm (1.600 in.) 51.31 mm (2.020 in.) 5.33 mm (0.210 in.)
4 Down relief valve plug Oring 5.87 mm (0.231 in.) 9.12 mm (0.359 in.) 1.63 mm (0.064 in.)
5 Manual release valve and tilt relief valve plunger 2.90 mm (0.114 in.) 6.45 mm (0.254 in.) 1.78 mm (0.070 in.)
6 Pumptomanifold Oring 3.68 mm (0.145 in.) 7.24 mm (0.285 in.) 1.78 mm (0.070 in.)
7 Manual release valve Oring 4.47 mm (0.176 in.) 8.03 mm (0.316 in.) 1.78 mm (0.070 in.)
Manual release valve, makeup check valve, and
8 6.07 mm (0.239 in.) 9.63 mm (0.379 in.) 1.78 mm (0.070 in.)
pressure operated check spool valve Oring
9 Tilt relief valve body Oring 7.65 mm (0.301 in.) 11.20 mm (0.441 in.) 1.78 mm (0.070 in.)
10 Pressure operated check seat Oring 9.25 mm (0.364 in.) 12.80 mm (0.504 in.) 1.78 mm (0.070 in.)
11 Pressure operated check cap Oring 12.42 mm (0.489 in.) 15.97 mm (0.629 in.) 1.78 mm (0.070 in.)
12 Reservoir plug Oring 13.94 mm (0.549 in.) 19.17 mm (0.755 in.) 2.62 mm (0.103 in.)
13 Motortomanifold Oring 66.27 mm (2.609 in.) 73.33 mm (2.887 in.) 3.53 mm (0.139 in.)
Trim Cylinder Rod Installation

1. Install a new lubricated Oring onto the memory piston.
a - Memory piston
b - Oring
a
b
48711
Page 5C-44 90-8M0082471 JULY 2014

Power Trim
2. Install new lubricated Orings onto the end cap and shock piston.
b a - End cap Oring

a
b - Shock piston Oring
55558

Fluid
3. Place the trim cylinder in a soft jawed vice.
4. Place the memory piston into the cylinder bore. Push the memory piston all the way to bottom.
5. Fill the cylinder 75 mm (3 in.) from top of the cylinder using Power Trim and Steering Fluid. If not available, use automotive
automatic transmission fluid (ATF).

114 Power trim system 92-858074K01
Fluid
6. Install the trim rod into the cylinder until power trim fluid flows through the oil blow off ball passage. Fill the cylinder to just
below the cylinder threads.
a a - Memory piston
b - Oring
b c - Oil blow off ball passage
7140
IMPORTANT: The end cap must not make contact with the trim rod piston when tightening. The trim rod piston must be
positioned in cylinder deep enough to avoid contact.
7. Tighten the end cap securely using a spanner wrench (6.4 mm x 8 mm [1/4 in. x 5/16 in.] long pegs). If a torquing type
spanner tool is used to tighten the end cap, then tighten to the specified torque.
Spanner Wrench 91 74951


End cap 61 45
90-8M0082471 JULY 2014 Page 5C-45

Power Trim
PressureOperated Check Valve

1. Install lubricated Orings onto the shuttle spool, seats, and the pressureoperated check valve plugs.
a c a
b b a - Plug
b - Seat
c - Shuttle spool
55548

Fluid
2. Install the seat, poppet, spring, and plug into forward side of the pressureoperated check valve bore. Tighten the plug to

Pressureoperated check valve plug 14 124
3. Install the shuttle spool, seat, poppet, spring, and plug into the aft side of the pressureoperated check valve bore. Tighten
the plug to the specified torque.
e a- Shuttle spool
c d b- Seat
b c- Poppet
d- Spring
e- Plug
a
c b
d
e
55519

Pressureoperated check valve plug 14 124
Down Pressure Relief Valve

1. Install a lubricated Oring onto the down relief valve plug.
2. Install the up pressure spring, spring guide, ball, and plug into the up pressure relief valve bore.
Page 5C-46 90-8M0082471 JULY 2014

Power Trim
3. Tighten the plug to the specified torque.
Down relief valve components

a - Spring
b - Spring guide/seat
c - Ball
d - Plug
a
b c d
55523

Relief valve plug 3 27
Tilt Relief Valve

1. Install lubricated Orings onto the spool housing and plunger.
2. Install the spring and poppet into the trim relief manifold bore. Ensure that the poppet is square with the bore.
3. Insert the spool housing into the bore. Ensure that the poppet pin protrudes into the hole in the spool.
4. Install the plunger into the trim limit spool.
5. Install two lubricated Orings into the trim manifold.
6. Install the three dowel pins into the trim manifold.
a- Tilt relief assembly

b- Spring
c- Poppet
d- Spool housing
e- Plunger
f- Oring (2)
g- Dowel pin (3)
g
f
d
e
a
b
c
55549
Manifold and Cylinder

1. Ensure that the Orings are in place on the power trim manifold.
2. Align the dowel pins and assemble the cylinder to the manifold.
90-8M0082471 JULY 2014 Page 5C-47

Power Trim
3. Secure the cylinder and manifold with two screws. Tighten the screws to the specified torque.
a - Screw (0.25020 x 2.25 in.)
a 55522

Trim cylinder screw (0.25020 x 2.25 in.) 15 133
Trim Pump and Motor

1. Install new lubricated Orings onto the pump.
2. Install the make up oil check seat and check ball.
3. Install the pump onto the manifold . Tighten the screws to the specified torque.
a b a - Make up oil check seat, Oring, and check ball

c
b - Dowel bushing
c - Pump Orings
55524
4. Install the two screws securing the pump to the base. Tighten the screws to the specified torque.
5. Install the coupler onto the pump shaft.
a a - Pump
b b - Screw (1032 x 1.625)
c - Coupler
55521
Page 5C-48 90-8M0082471 JULY 2014

Power Trim

Pump mounting screws 8 71
6. Install the motor Oring.
a - Oring
b - Drive tang
55525
7. Align the coupler to the motor shaft and install the motor onto the base.
a - Motor
b - Screw (M6 x 35) and washer
b
b
55518

Motor mounting screws (M6 x 35) 9 80
Power Trim System Installation

1. Apply 24C with PTFE to the lower pivot pin bore and pivot pin surface.
2. Position the trim cylinder assembly, bottom first, between the clamp brackets and route the trim pump electrical harness
through the access hole in the starboard clamp bracket.
3. Insert the lower pivot pin into pivot pin bore.
90-8M0082471 JULY 2014 Page 5C-49

Power Trim
4. Using a suitable punch, drive the lower pivot pin into the clamp bracket and trim cylinder assembly until the pivot pin is
flush with the outside surface.
a - Lower pivot pin

b - Anchor bracket
c - Trim cylinder assembly
a b c
55550

95 2-4-C with PTFE Pivot pin surface and lower pivot pin bore 92-802859A 1
5. Insert a trilobe pin into the hole in the anchor bracket.
6. Using a suitable punch, drive the trilobe pin into the anchor bracket until seated.
7. Secure the ground cable to the sacrificial aluminum anode with a screw and washer. Tighten the screw to the specified
torque.
a- Sacrificial anode
b- Screw (M6 x 25) and washer
c- Ground cable
d- Lower trilobe pin
c
a
b 55555

Ground cable screw (M6 x 25) 8 71
8. Ensure that the upper pivot bearings are installed.
Page 5C-50 90-8M0082471 JULY 2014

Power Trim
9. Apply 24C with PTFE to the surface of the upper pivot pin, pivot pin bore, and trim ram bore.
a - Upper pivot bearings

b
55177

95 2-4-C with PTFE Upper pivot pin and bore, trim ram bore 92-802859A 1
10. Align the power trim cylinder rod eye and the swivel bracket cross holes.
NOTE: The chamfered hole in the rod eye faces aft.
11. Insert the upper pivot pin, with the slotted end inserted first, through the swivel bracket and power trim cylinder rod eye.
IMPORTANT: The slotted end of the pivot pin faces port.
a - Slotted end of pivot pin

b - Chamfered hole of rod eye
b
55258
12. Insert a punch into the trim cylinder rod eye to align the cross hole in the upper pivot pin.
13. Install the trilobe pin into the upper pivot pin and trim cylinder rod eye.
a a- Upper pivot pin (slot is in line with cross hole)

b- Chamfered hole in rod eye (faces aft)
c- Trilobe pin
d- Trim ram
c b
9201
90-8M0082471 JULY 2014 Page 5C-51

Power Trim
14. Route the trim position sensor and power trim motor harnesses. Secure the harnesses with two Jclips and a screw.
15. Install the trim position sensor to the swivel bracket with the potted surface toward the bracket and secure with two screws.
Tighten to the specified torque.
a- Trim sensor
harnesses
d
b
c
55175

Trim position sensor mounting screws 1.7 15
16. Connect the power trim motor leads to the power trim relay harness.
17. Check the fluid level.
18. Connect the battery leads to the battery terminals.
19. The power trim may now be operated to lower the outboard to the desired position. The trim system is selfpurging.
20. Install the spark plug leads to the spark plugs.
21. Install the cowls.
Page 5C-52 90-8M0082471 JULY 2014

Standard Right-Hand Rotation Gear Housing
Gear Housing
Section 6A - Standard Right-Hand Rotation Gear Housing
Table of Contents
Standard Gear Housing Specifications.............................. 6A-2 Propeller Shaft Inspection.........................................6A-24
Gear Housing Driveshaft Components.............................. 6A-8 Propeller Shaft Disassembly.....................................6A-25
Gear Housing (Propeller Shaft RightHand Rotation)...... 6A-12 Pinion Gear and Driveshaft Removal...............................6A-26
General Service Recommendations................................ 6A-14 Driveshaft Cleaning and Inspection.......................... 6A-28
Bearings....................................................................6A-14 Forward Gear Disassembly............................................. 6A-28
Shims........................................................................6A-14 Cleaning and Inspection........................................... 6A-29
Seals.........................................................................6A-14 Gear Housing Inspection................................................. 6A-30
Gear Housing Removal ...................................................6A-14 Pinion Bearing Installation............................................... 6A-30
Gearcase Service Inspection........................................... 6A-16 Bearing Carrier Assembly................................................ 6A-31
Draining and Inspecting Gear Housing Lubricant..... 6A-16 Forward Gear Assembly.................................................. 6A-34
Propeller Shaft Inspection.........................................6A-16 Forward Gear Bearing Race Assembly........................... 6A-35
Water Pump Removal and Disassembly......................... 6A-17 Driveshaft Assembly........................................................ 6A-36
Cleaning and Inspection........................................... 6A-18 Pinion Gear Depth........................................................... 6A-39
6
Oil Seal Carrier Assembly................................................6A-19 Forward Gear Backlash................................................... 6A-42
Removal....................................................................6A-19 Propeller Shaft Assembly.................................................6A-43
Disassembly............................................................. 6A-20 Reverse Gear Backlash (Standard Rotation)...................6A-48
Bearing Carrier and Propeller Shaft Removal .................6A-20
Shift Shaft Inspection................................................6A-22
Water Pump Assembly.................................................... 6A-49
Gear Housing Pressure Test........................................... 6A-51
A
Bearing Carrier Disassembly........................................... 6A-23 Gear Housing Installation.................................................6A-52
Propeller Shaft Inspection and Disassembly................... 6A-24 Gear Lubricant Filling Instructions................................... 6A-54
90-8M0082471 JULY 2014 Page 6A-1

Standard Gear Housing Specifications

RightHand Gear Housing Specifications (Standard)
Water pressure
At 5800 RPM (WOT) 80300 kPa (11.643.5 psi)

Outside diameter of outer propeller shaft oil seal
7 Loctite 271 Threadlocker Threads of the pinion nut 92-809819
Pinion nut threads
19 Perfect Seal Outside diameter of shift shaft seal 92-34227Q02
Inside diameter of the reverse gear ball bearing
Outside diameter of the propeller shaft needle bearing
Outside diameter of the reverse gear ball bearing
High Performance Gear Center bore of the forward gear
87 92-858064K01
Lubricant Inside diameter of the forward gear tapered bearing
Inside diameter of driveshaft tapered bearing
Inside diameter of upper driveshaft tapered bearing
Gear housing
Engine Coupler Spline
91 Driveshaft splines and shift shaft splines 8M0071842
Grease
Pinion bearing bore
Oil seal lips and O-ring
Outside diameter of forward gear bearing race
Bearing retainer
Cam follower pocket
95 2-4-C with PTFE 92-802859A 1
Shift shaft bushing O-ring and seal lip
O-ring and outside diameter of bearing carrier
Threads of the retainer nut
Oil seal carrier O-ring and seal lips
Inside of water pump cover
117 Loctite 7649 Primer N Pinion nut threads 92-809824
Special Tools
Dial Indicator 91 58222A 1
Used to obtain a variety of measurements including gear backlash, pinion gear

location, and TDC.
9479
Page 6A-2 90-8M0082471 JULY 2014

Dial Indicator Adapter 9183155
Dial indicator holding fixture

2999
Dial Indicator Holding Tool 9189897
Secures the dial indicator to gear housing when checking backlash
29496
Bearing Carrier Retainer Nut Wrench 8M0057002
Installs and removes the bearing carrier retainer nut
46139
Puller Jaws Assembly 9146086A1
Removes bearing carrier and bearing races; use with Puller Bolt (9185716)
9514
Slide Hammer 9134569A 1
Aids in the removal of various engine components. Use with puller jaws.
6761
Universal Puller Plate 9137241
Removes bearings from gears and the driveshaft
8505
90-8M0082471 JULY 2014 Page 6A-3

Bearing Removal and Installation Kit 9131229A 7

Installs and removes the bearings in all gearcase. All components can be
purchased separately.
9131229A 7 tool assembly includes the following components:
1124156 Hex Nut
1234961 Washer
9115755T Needle Bearing Driver
9129310 Plate
9130366T 1 Mandrel
9131229 Puller Shaft
9132325T Driver Head
9132336 Needle Bearing Driver
9136379 Puller and Head Gear
9136571T Pilot Washer
9137292 Roller Bearing
9137311 Driver Head
2966 9137323 Driver Head Rod
9137350T Pilot Mandrel
9138628T Puller and Driver Head
9152393T Pinion Bearing Installation Tool
9152394 Head Pull Rod
Driveshaft Bearing Retainer Wrench 9143506T
Removes and installs the threaded bearing retainer
9520
Driveshaft Holding Tool 91889958T
Holds driveshaft during pinion nut removal on the Verado models
28677
Bearing Removal and Installation Kit 918M0077654
1
Removes and installs the lower driveshaft bearing. 1) 8M0077647 Driver rod 2)
8M0077645 Pilot 3) 8M0077630 Bushing
2 3 56240
Needle Bearing Driver 9115755T
Installs needle bearings into bearing carriers
10787
Page 6A-4 90-8M0082471 JULY 2014

Oil Seal Driver 9131108T
Installs bearing carrier oil seals
8883
Torch Lamp 9163209
Heats surfaces to aid in the removal and installation of interference fit engine
components
8776
Mandrel 918M0077816
Installs the needle bearing into the forward gear
48574
Bearing Cup/Adapter Installation Tool 918M0057767
Installs the forward gear bearing race on the standard righthand gear case.
Presses the reverse gear bearing adapter into the gear housing on the counter
lefthand gear case
49525
Pilot Ring 918M0074763
Aligns the bearing cup installation tool in the gearcase bore
56249
Retainer Installer Tool 918M0074757
Installs
56237
Bearing Cup Driver 918M0077786
Installs the forward gear bearing cup

9445
90-8M0082471 JULY 2014 Page 6A-5

Driveshaft Bearing Installation Tool 918M0052590
Install upper and lower driveshaft bearings
47416
Bearing Preload Tool 9114311A04
Simulates a load on the driveshaft for accurate pinion height and backlash
measurements
8756
Pinion Gear Locating Tool 918M0089163
2
3
1
4
8
7 5
6
Measures pinion gear height
56235
Pinion Gauge Adapter Tool 918M0070993
Allows pinion measuring gauge to fit the front gear bearing
56254
Locating Disc #5 918M0074768
Provides an access hole to measure the pinion depth
49549
Backlash Indicator Rod 9178473
Aids in checking gear backlash

9450
Page 6A-6 90-8M0082471 JULY 2014

Driveshaft Seal Installation Tool 91818769
Sets driveshaft seal height

47536
Leakage Tester Kit FT8950
Used for pressure testing of closed systems (gearcase, fuel lines, cooling).
29497
90-8M0082471 JULY 2014 Page 6A-7

Gear Housing Driveshaft Components

20
19
20
21
22 23
24
25
26
27
18
12 11
28
29
30
13 31
32
14 38 33
15 34
39
16 35
40
17 36
41
9
5
37
7
6
4
6
8
2 10
3
1
55146
Page 6A-8 90-8M0082471 JULY 2014


Torque
1 1 Gearcase housing
2 2 Vent screw 11.3 100
3 4 Seal
4 1 Dowel pin
5 1 Dowel pin (without hole)
6 2 Anode
7 1 Screw (M6 x 40) 6.8 60
8 1 Nut (M6)
9 1 Screw (0.43714 x 1.750) 54 40
10 1 Trim tab anode
11 1 Lower shift shaft
12 1 Ering
13 1 Retaining ring
14 2 Washer
15 1 Oil seal
16 1 Bushing assembly
17 1 Oring
18 1 Driveshaft
19 1 Water pump coupling
20 2 Oring
21 4 Screw (M6 x 20) 6.8 60
22 1 Face seal
23 1 Filler block
24 1 Water pump housing
25 1 Key
26 1 Water pump impeller
27 1 Faceplate
28 1 Retaining ring
29 1 Oil seal carrier assembly
30 2 Oil seal (the oil seal is not serviceable)
31 1 Oring
32 1 Retainer 135.5 100
33 1 Cup (not sold separate)
34 1 Tapered roller bearing
35 1 Shim
36 1 Roller bearing assembly
37 1 Shim set
38 1 Needle bearing
39 1 Pinion gear (14 teeth) (not sold separate)
40 1 Washer
90-8M0082471 JULY 2014 Page 6A-9

Torque
41 1 Nut (0.62518) 101.7 75
Page 6A-10 90-8M0082471 JULY 2014


20
19
20
21
22 23
24
25
26
27
18
12 11
28
29
30
13 31
32
14 38 33
15 34
39
16 35
40
17 36
41
9
5
37
7
6
4
6
8
2 10
3
1
55146
90-8M0082471 JULY 2014 Page 6A-11

Gear Housing (Propeller Shaft RightHand Rotation)
14
11
13
12
2
3 27
10 4
5 26
6
25
7
8 24
9 23
20
19
18 21
17 22
16
15
55147
Page 6A-12 90-8M0082471 JULY 2014

Gear Housing (Propeller Shaft Right-Hand Rotation)

Torque
1 1 Gearcase
2 1 Forward gear (29 teeth)
3 1 Needle bearing
4 1 Retaining ring
5 1 Tapered roller bearing cone (1.9685 I.D.)
6 1 Tapered roller bearing cup (3.5433 O.D.)
7 1 Shim
8 1 Clutch actuator rod
9 1 Cam follower
10 1 Shift cam
11 1 Sliding clutch
12 1 Cross pin
13 1 Spring
14 1 Propeller shaft
15 1 Reverse gear (29 teeth)
16 1 Ball bearing (0.3125 in. diameter)
17 1 Thrust ring
18 1 Oring
19 1 Bearing carrier spool
20 1 Needle bearing
21 1 Fill screw 11.3 100
22 1 Seal
23 1 Oil seal
24 1 Seal
25 1 Tab washer
26 1 Bearing carrier retainer 285 210
27 1 Propeller bore sleeve
90-8M0082471 JULY 2014 Page 6A-13

General Service Recommendations

There may be more than one way to disassemble or assemble a particular part. It is recommended the entire procedure be
read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
Disassembly of a subassembly may not be necessary until cleaning and inspection reveals that disassembly is required for
replacement of one or more components.
Service procedure order in this section is a normal disassembly/assembly sequence. The sequence should be followed without
deviation to assure proper repairs. When performing partial repairs, follow the instructions to the point where the desired
component can be replaced, then proceed to assembly and installation of that component in the assembly part of this section.
Use the Table of Contents to find the correct page number.
Threaded parts are righthand (RH), unless otherwise indicated.
When holding, pressing, or driving is required, use soft metal vise jaw protectors or wood for protection of parts. Use a suitable
mandrel that will contact only the bearing race when pressing or driving bearings.
Whenever compressed air is used to dry a part, verify that no water is present in the air line.
Bearings
Upon disassembly of the gear housing, all bearings must be cleaned and inspected. Clean the bearings with solvent and dry
with compressed air. Air should be directed at the bearing so that it passes through the bearing. Do not spin the bearing with
compressed air, as this may cause the bearing to score from lack of lubrication. After cleaning, lubricate the bearings with High
Performance Gear Lubricant. Do not lubricate the tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches, and bearing race side wear. Work the inner bearing race in and out, while holding
the outer race, to check for side wear.
When inspecting the tapered bearings, determine the condition of the rollers and the inner bearing race by inspecting the
bearing cup for pits, scoring, grooves, uneven wear, imbedded particles, and/or discoloration from overheating. Always replace
the tapered bearing and race as a set.
Inspect the gear housing for bearing races that have spun in their respective bores. If the race has spun, the gear housing must
be replaced.
Roller bearing condition is determined by inspecting the bearing surface of the shaft that the roller bearing supports. Check the
shaft surface for pits, scoring, grooves, imbedded particles, uneven wear, and/or discoloration from overheating. The shaft and
bearing must be replaced if the conditions described are found.
Shims
Keep a record of all shim amounts and their location during disassembly to aid in assembly. Be sure to follow the shimming
instructions during assembly, as gears must be installed to the correct depth and have the correct amount of backlash to avoid
noisy operation and premature gear failure.
Seals
As a normal procedure, all Orings and oil seals should be replaced without regard to appearance. To prevent leakage around
oil seals, apply Loctite 271 Threadlocker to the outer diameter of all metal case oil seals. When using Loctite on seals or
threads, the surfaces must be clean and dry. To ease installation, apply 24C with PTFE on all Orings. To prevent wear, apply
24C with PTFE on the l.D. of oil seals.
Gear Housing Removal

! WARNING
1. Disconnect both battery leads from the battery.

2. Shift the gearcase into neutral position.
3. Tilt the engine up and engage tilt lock lever.
Page 6A-14 90-8M0082471 JULY 2014

4. Bend the tabs of the propeller tab washer away from the thrust hub and remove the propeller locknut, tab washer,
propeller, and thrust hub from the propeller shaft.
b a- Tab washer
a b- Continuity washer (if equipped)
f
c- Propeller locknut
d- Rear thrust hub
e- Propeller shaft
f- Front thrust hub
d c e
48808
5. Mark the position of the trim tab, if equipped, so it can be installed in the same position.
6. Remove the rubber cover at the rear edge of the driveshaft housing.
a a - Rubber cover
55957
7. Remove the screw securing the anodic plate, or trim tab if equipped, and remove the anodic plate.
8. Remove the screw from the inside of the anodic plate cavity.
a - Screw
48236
9. Loosen the side mounting locknuts.
90-8M0082471 JULY 2014 Page 6A-15

NOTE: Do not attempt to remove one locknut before the opposite side mounting locknut is loosened.
a - Locknuts and washers (2 each side)
48245
10. Pull the gear housing away from the driveshaft housing as far as the loosened locknuts will allow and remove the locknuts.
11. Pull the gear housing from the driveshaft housing.
Gearcase Service Inspection

Draining and Inspecting Gear Housing Lubricant
1. Place the gear housing in a suitable holding fixture or vise with the driveshaft in a vertical position.
2. Position a clean drain pan under the gear housing and remove the fill and vent screws from the gear housing.
a - Fill screw
b - Vent screw
a
48252
3. Inspect the gear lubricant for metal particles. Presence of a small amount of fine metal particles resembling powder
indicates normal wear. Presence of larger particles, or a large quantity of fine particles, indicates the gear housing should
be disassembled and inspected.
4. Note the color of the gear lubricant. White or cream color indicates the presence of water in the lubricant. Check the drain
pan for water separation from the lubricant. Presence of water in the gear lubricant indicates the gear housing should be
disassembled and inspected.
Propeller Shaft Inspection

1. Install the dial indicator adapter to the gearcase and attach the dial indicator.
2. Rotate the propeller shaft while observing the dial indicator. If the runout is more than 0.152 mm (0.006 in.), a bent
propeller shaft is indicated.
Page 6A-16 90-8M0082471 JULY 2014

3. Push in and pull out on the propeller shaft to determine propeller shaft end play. Propeller shaft end play should be
0.1271.905 mm (0.0050.075 in.). If the propeller shaft end play is not within specification, the gearcase should be
disassembled for inspection.
c a- Propeller shaft out of round

b- Propeller shaft end play
d c- Dial indicator
a d- Dial indicator holding tool
e- Dial indicator adapter
3234
Propeller Shaft
Runout 0.152 mm (0.006 in.)
End play 0.1271.905 mm (0.0050.075 in.)

Water Pump Removal and Disassembly

1. Remove the water tube coupler.
2. Slide the Vring face seal off the driveshaft.
3. Remove and retain the four screws securing the water pump cover to the gear housing.
4. Lift the water pump cover off the driveshaft.
NOTE: If tools are used to pry the water pump cover up, protect the surface of the gearcase where the tools contact to
prevent damage to the paint which may result in future corrosion.
a- Water tube coupler

b- Vring face seal
c- Water pump cover
a b c d- Screws (M6 x 20) (2 each side)
d
55949
5. Remove the impeller from the driveshaft.

NOTE: It may be necessary to use a hammer and chisel to remove the impeller or split the hub of the impeller.
6. Remove the impeller drive key from the driveshaft.
90-8M0082471 JULY 2014 Page 6A-17

7. Remove the water pump faceplate.
a - Impeller
b - Drive key
c - Faceplate with molded gasket
a
c b
55950
Cleaning and Inspection

NOTE: With the gear housing removed, inspect the water tube coupler assembly inside the driveshaft housing for wear or
damage. Replace worn or damaged components.
IMPORTANT: The circular groove formed by the impeller will not affect the water pump output.
1. Inspect the faceplate for grooves or rough surfaces. Inspect the molded gasket material for damage.
a b c
55951
a - Water pump impeller side of faceplate

b - Molded gasket material
c - Bottom side molded gasket material
2. Inspect the water pump liner for grooves or rough surfaces.
55952
3. Inspect the impeller seal surfaces and the ends of the impeller blades for cracks, tears, and wear. Replace the impeller if
any of these conditions are found.
Page 6A-18 90-8M0082471 JULY 2014

4. Inspect the keyway and impeller bonding to the impeller hub.
b a - Impeller
a b - Keyway/impeller hub
55953
5. Inspect the impeller for glazed or melted appearance caused by operation without sufficient water supply. Replace the
impeller if any of these conditions are found.
IMPORTANT: When completing gear housing repairs that require removal of the water pump impeller, it is recommended
the impeller be replaced. However, if the impeller must be used, do not install in reverse to the original rotation; premature
impeller failure will occur.
Oil Seal Carrier Assembly

Removal
1. Remove the retaining ring securing the oil seal carrier.
a - Oil seal carrier

b - Retaining ring
48281
NOTE: When prying the oil seal carrier up, protect the surface of the gearcase where the tools contact to prevent damage
to the paint which may result in future corrosion.
2. Use suitable tools to remove the oil seal carrier from the gearcase assembly.
c a - Oil seal carrier

b - Oil seal carrier pry points
c - Protective pad
a
c
b
48284
90-8M0082471 JULY 2014 Page 6A-19

3. Remove and discard the Oring from the oil seal carrier.
NOTE: If the oil seals within the seal carrier require replacement, the oil seal carrier must be replaced as an assembly.
a a - Oil seal carrier

b - Oring
48291
Disassembly
NOTE: The oil seals within the oil seal carrier are not individually replaceable. If the oil seals require replacement, the oil seal
carrier must be replaced as an assembly.
Bearing Carrier and Propeller Shaft Removal

1. Place the gear housing in a suitable holding fixture with the propeller shaft in a horizontal position.
2. Use the shift shaft to shift the gear housing into neutral.
IMPORTANT: The gear housing must be in neutral before the propeller shaft can be removed.
3. Remove the gear housing oil drain screw.
4. Bend the retainer nut lock tabs out of the retainer nut recesses.
a - Bearing carrier retainer nut

b - Propeller bore sleeve
c - Lock tabs
a
b
c
48306
Page 6A-20 90-8M0082471 JULY 2014

5. Remove the bearing carrier retainer nut and propeller bore sleeve with the bearing carrier retainer nut wrench.
a - Bearing carrier retainer nut wrench

a
55955

6. Remove the locking tab washer from the gear housing.
a - Locking tab washer
48311
7. Verify that the gear housing is in neutral. Remove the shift washer and retaining ring.
8. Remove the shift shaft and bushing.
a- Shift shaft
a
c- Rubber washer
b d- Retaining ring
d
c
55954
90-8M0082471 JULY 2014 Page 6A-21

9. Remove and discard the shift shaft bushing Oring.
a - Shift shaft bushing Oring

a
48317
10. Use the long puller jaws and puller bolt to remove the bearing carrier.
NOTE: Use the propeller thrust hub to maintain pressure on the puller jaws.
d
a
b
48555
a- Long jaws
b- Puller bolt
c- Thrust hub
d- Shift shaft bushing
e- Shift shaft

11. Remove the propeller shaft, cam follower, and shift cam by pulling the propeller shaft straight out of the gear housing. Do
not jerk the propeller shaft out of the gear housing. If propeller shaft will not come out, proceed as follows:
Push the propeller shaft back into place against the forward gear. Visually inspect the location of the shift cam by looking down
the shift shaft hole. If the splined hole in the shift cam is visible, install the shift shaft and rotate the shift shaft into the neutral
position. Remove the shift shaft and then remove the propeller shaft.
Shift Shaft Inspection

1. Clean the shift shaft and bushing with a mild solvent and dry with compressed air.
2. Check the shift shaft splines for wear, corrosion, or damage.
3. Inspect the shift shaft for grooves at the seal area.
4. Inspect the bushing for damage.
5. If any of these conditions exist, replace the shift shaft.
Page 6A-22 90-8M0082471 JULY 2014

Bearing Carrier Disassembly

1. Remove and discard the Oring on the bearing carrier.
2. Secure the bearing carrier in a soft jaw vise.
IMPORTANT: Clamp on the raised reinforcing rib on the bearing carrier when securing the carrier in a vise to prevent
damage to the carrier.
3. Use a slide hammer to remove the reverse gear assembly.
e a- Bearing carrier
c b- Oring
b d c- Spacer
d- Reverse gear
e- Slide hammer
a
f- Raised reinforcing rib
48321
f
4. Use the universal puller plate and a suitable mandrel to press the gear off the bearing.
5. If the reverse gear bearing remained in the bearing carrier, use the slide hammer to remove the bearing.
a- Universal puller plate

b- Bearing
c- Gear
d d- Mandrel
b
c
33975

6. Inspect the reverse gear to pinion gear wear pattern. It should be even and smooth. If not, replace the reverse gear, pinion
gear, and forward gear.
7. Inspect the reverse gear for pitted, chipped or broken teeth, and hairline fractures. Replace the reverse gear and the pinion
gear if any defects are found.
90-8M0082471 JULY 2014 Page 6A-23

8. Check the clutch jaws on the reverse gear for damage. Replace the reverse gear if damage is found.
b a - Reverse gear
b - Clutch jaws
a
49529
9. Remove the propeller shaft oil seals with a pry bar or slide hammer.
NOTE: Do not damage the inside diameter of the bearing carrier when removing the propeller shaft seals.
10. Press the propeller shaft needle bearing out of the bearing carrier with a suitable mandrel.
d 35535
a- Pry bar
b- Propeller shaft needle bearing
c- Mandrel
d- Oil seals
Propeller Shaft Inspection and Disassembly

1. Clean the propeller shaft assembly with solvent and dry with compressed air.
2. Inspect the propeller shaft oil seal for grooves. Replace the shaft if grooves are found.
3. Visually inspect the bearing surfaces of the propeller shaft for pitting, grooves, scoring, uneven wear, or discoloration from
overheating. Replace the shaft and corresponding needle bearing if any of the previous mentioned conditions are found.
4. Check the propeller shaft for runout.
Page 6A-24 90-8M0082471 JULY 2014

Position the propeller shaft roller bearing surfaces on Vblocks. Use a dial indicator at the front edge of the propeller
splines. Rotate the propeller shaft. Dial indicator movement more than the specification requires the propeller shaft to
be replaced.
a - Vblocks
b - Bearing surfaces
c - Dial indicator location
b
b
a
c
48396
Propeller Shaft
Runout 0.152 mm (0.006 in.)

5. Inspect the propeller shaft splines for wear or corrosion damage.
6. Inspect the sliding clutch jaws. Rounded clutch jaws indicate one or more of the following conditions:
Improper shift cable adjustment
Improper shifting technique shifting too slow
Engine RPM too high while shifting
a b a - Reverse gear clutch dog teeth

b - Forward gear clutch dog teeth
48326
Propeller Shaft Disassembly

1. Remove the shift cam from the cam follower.
2. Insert a thin blade screwdriver or awl under the first coil of the cross pin retaining spring and rotate the propeller shaft to
unwind the spring from the clutch. Do not overstretch the spring.
a a - Cross pin retaining spring

b - Awl
c - Shift cam
c
b
55935
90-8M0082471 JULY 2014 Page 6A-25

3. Push the cross pin out of the sliding clutch and propeller shaft.
a a - Sliding clutch
b - Cross pin
b 55936
4. Remove the cam follower and clutch actuator rod from the propeller shaft.
a- Sliding clutch
b- Cross pin
c- Propeller shaft
d- Clutch actuator rod
e- Cam follower
d e
a c
b
55937
5. Remove the sliding clutch from the propeller shaft.

6. Clean the clutch actuator rod and cam follower in a mild solvent. Dry with compressed air and inspect the components for
wear or damage.
Pinion Gear and Driveshaft Removal

1. Use the driveshaft bearing retainer wrench to remove the driveshaft bearing retainer.
a - Bearing retainer
b - Driveshaft bearing retainer wrench
48340

2. Install the driveshaft holding tool onto the driveshaft splines.

3. Use a socket and flex handle to hold the pinion nut.
NOTE: Use a rag to protect the gear housing from damage.
4. Use the driveshaft holding tool to loosen the pinion nut.
Page 6A-26 90-8M0082471 JULY 2014

5. Remove the pinion nut and the driveshaft holding tool.
6. Remove the driveshaft by pulling the driveshaft straight out of the gear housing.
7. If the pinion gear is seized onto the driveshaft, clamp the driveshaft in a soft jaw vise.
8. Place a block of wood on the gear housing mating surface. Use a mallet and carefully tap the gear housing away from the
driveshaft.
IMPORTANT: Striking a gear housing directly with a mallet can distort the gear housing causing gear housing failure.
IMPORTANT: The pinion bearing rollers can fall out of the pinion bearing race after the driveshaft is removed. Do not lose
the 18 rollers.
a - Wood block
b - Soft jaw vise covers
b a
48341
9. Remove the pinion gear and forward gear assembly from the gear housing.
10. Remove the driveshaft tapered bearing shims and record the total dimension.
11. Install the universal puller plate.
12. Position the driveshaft in the vise as shown. Do not tighten the vise jaws directly against the driveshaft. Use soft jaw vise
covers.
13. Strike the driveshaft with a deadblow hammer to remove the upper driveshaft bearing.
14. Repeat the procedure to remove the lower bearing.
a - Upper bearings
b - Universal puller plate
c - Lower bearing (hidden)
a
56202

15. Install the pinion bearing rollers if they have fallen out. All of the rollers must be installed to remove the pinion bearing race.
16. Place the bushing into the driveshaft bore until it rests on the bearing.
17. Place the bearing driver pilot tool into the driveshaft bore.
18. Install the driver rod into the pilot tool and bushing.
19. Use a hammer to remove the pinion bearing and discard the pinion bearing.
90-8M0082471 JULY 2014 Page 6A-27

20. Inspect the pinion gear for pitting, grooves, scoring, uneven wear, or discoloration from overheating. Replace the pinion
gear set if any of these conditions are found.
a- Pilot
b- Driver rod tool
c- Bushing
a d- Bearing
56239
Driveshaft Cleaning and Inspection

1. Clean all parts with a suitable solvent and dry with compressed air. Do not spin the bearings.
! WARNING
Spindrying bearings with compressed air can cause serious injury or death. The bearings can explode, even if spun at very
slow speeds. Do not allow the bearings to spin when drying with compressed air.
2. Inspect the driveshaft bearing cups for pitting, grooves, uneven wear, discoloration, or embedded particles. Replace the
bearings and bearing cups if any of these conditions are found.
3. Inspect the driveshaft pinion bearing surface area for pitting, grooves, scoring, uneven wear, or discoloration. Replace the
driveshaft if any of these conditions are found.
4. Inspect the splines at both ends of the driveshaft for a worn or twisted condition. Replace the driveshaft if any of these
conditions are found.
5. Inspect the driveshaft water pump base oil seal area for grooves. Replace the driveshaft if grooves are found.
b a - Splines
a c a
b - Pinion bearing surface
c - Seal contact area
56198
Forward Gear Disassembly

1. Remove the retaining ring securing the propeller shaft needle bearing.
2. Place the forward gear, with the teeth side up, into a soft jaw vise.
Page 6A-28 90-8M0082471 JULY 2014

3. Use a punch and hammer to remove the propeller shaft needle bearing and discard the bearing.
b 35566
a - Retaining ring
b - Bearing
4. Install the universal puller plate between the forward gear and tapered bearing.
5. Press the gear off the bearing with a suitable mandrel. Discard the bearing.
6. Remove the forward gear tapered bearing race from the gear housing with a slide hammer and retain the shims that are
behind the forward gear tapered bearing race.
b
c
a
d 35562

b- Mandrel
c- Slide hammer
d- Tapered bearing race


1. Clean the forward gear with a mild solvent and dry with compressed air.
! WARNING
90-8M0082471 JULY 2014 Page 6A-29

2. Inspect the gear teeth for pitting, grooves, scoring, uneven wear, and discoloration. Replace the gear if any of these
3. Inspect the clutch dogs for damage. Replace the gear if damage is found.
Gear Housing Inspection

1. Clean the gear housing thoroughly with a suitable solvent and a hard bristle brush. Dry the gear housing thoroughly using
compressed air. Ensure all sealants, locking agents, and debris are removed.
2. Verify the two oil circulation holes in the driveshaft bore and the shift shaft hole are clear and free of debris.
3. Inspect the gear housing for excessive corrosion, impact, or any other damage. Excessive damage and/or corrosion
requires replacement of the gear housing.
4. Inspect the bearing carrier retainer threads in the gear housing for corrosion and/or stripped threads. Damage or corrosion
to the threads requires replacement of the gear housing.
NOTE: The upper and lower driveshaft bearing cups are a slip fit within the driveshaft bore and may show signs of
movement. All other bearing cups are press fit and should not show any signs of movement.
5. Inspect bearing race/cup contact areas for evidence of bearing cup spinning. Check that bearing cups are not loose in
bearing bores. A press fit type bearing bore in which the race/cup is loose will require replacement of the gear housing.
6. Inspect for blockage in water inlet holes and the speedometer hole, clean as necessary. Be careful not to enlarge the
speedometer hole, as this could cause erroneous speedometer readings.
a
a - Oil circulation holes
b - Speedometer hole
c - Water inlet holes
49365
7. Verify the locating pins are in place in the gear housing and the corresponding holes in the driveshaft housing are not
elongated. The driveshaft may break if the housings are not aligned properly due to missing locating pins or elongated
holes.
Pinion Bearing Installation

IMPORTANT: Never install a pinion bearing that was removed from a gear housing. Always install a new pinion bearing.
1. Lubricate the gear housing pinion bearing bore with 24C with PTFE.
2. Install the driver rod into the pilot.
3. Install the pinion bearing onto the driver rod so the letter and number side of the bearing is facing up.
4. Insert the pilot, driver rod, and bearing into the gear housing pinion bearing bore.
Page 6A-30 90-8M0082471 JULY 2014

5. Press the driver rod until the bearing is fully seated.
a - Pilot
b - Driver rod
a c - Bearing
56243

95 2-4-C with PTFE Pinion bearing bore 92-802859A 1
Bearing Carrier Assembly

1. Place the reverse gear on a press with the gear teeth facing down.
2. Place the thrust washer over the gear.
3. Apply High Performance Gear Lubricant onto the inside diameter of the reverse gear ball bearing and position the ball
bearing onto the gear with the numbered side of the bearing facing up.
b a - Thrust washer
b - Mandrel
39699

High Performance Gear
87 Inside diameter of the reverse gear ball bearing 92-858064K01
Lubricant
4. Press the ball bearing onto the gear with a suitable mandrel until seated. Press only on the inner race of the bearing.
5. Apply High Performance Gear Lubricant onto the outside diameter of the propeller shaft needle bearing and place the
propeller shaft needle bearing with the numbers facing aft, into the bearing carrier.
90-8M0082471 JULY 2014 Page 6A-31

6. Press the bearing into the bearing carrier with the needle bearing driver tool until the tool is seated on the bearing carrier.
a - Needle bearing driver tool
48403

87 Outside diameter of the propeller shaft needle bearing 92-858064K01
Lubricant

7. Install the first seal onto the long shoulder side of the oil seal driver. Verify the seal lip faces away from the mandrel
shoulder. Press the seal into the bearing carrier until the oil seal driver contacts the bearing carrier.
a - Oil seal
b b - Oil seal driver
48361

8. Apply Loctite 271 Threadlocker to the outside diameter of the second (outer) propeller shaft oil seal.
Page 6A-32 90-8M0082471 JULY 2014

9. Install the second seal onto the short shoulder side of the oil seal driver. Verify the seal lip faces towards the oil seal driver
b a - Oil seal
b - Oil seal driver
48398

7 Loctite 271 Threadlocker Outside diameter of outer propeller shaft oil seal 92-809819
10. Remove excess Loctite 271 Threadlocker from the seal area.
11. Apply High Performance Gear Lubricant onto the outside diameter of the reverse gear ball bearing.
12. Place the bearing carrier over the thrust washer and the reverse gear assembly.
NOTE: Warming the bearing carrier with a torch lamp where the reverse gear assembly resides will aid in the installation of
the reverse gear assembly.
13. Use a suitable mandrel to press the bearing carrier onto the bearing.
a - Mandrel
b - Bearing seated
a c - Thrust washer
c 56248

87 Outside diameter of the reverse gear ball bearing 92-858064K01
Lubricant
Torch Lamp 9163209

14. Install an Oring between the bearing carrier and thrust washer.
90-8M0082471 JULY 2014 Page 6A-33

15. Apply 24C with PTFE to the oil seal lips and Oring.
95 a- Oring
b- Thrust washer
c- Reverse gear
c d- Propeller shaft seals (hidden)
95
a b 48476

95 2-4-C with PTFE Oil seal lips and O-ring 92-802859A 1
Forward Gear Assembly

1. Apply High Performance Gear Lubricant into the center bore of the forward gear.
2. Install the numbered side of the forward gear needle bearing onto the short shoulder side of the forward gear bearing tool.
NOTE: The bearing carrier needle bearing contacts the propeller shaft in front of the oil seal area. The forward gear
bearing contacts the propeller shaft in front of the clutch splines.
3. Press the bearing into the forward gear until the mandrel is against the gear.
a - Mandrel
b - Bearing
c - Forward gear
a
b
c
48568

87 Center bore of the forward gear 92-858064K01
Lubricant
Mandrel 918M0077816
4. Place the forward gear on a press with the gear teeth facing down.
5. Apply High Performance Gear Lubricant to the inside diameter of the forward gear tapered bearing and position the
forward gear tapered bearing over the gear.
Page 6A-34 90-8M0082471 JULY 2014

6. Use a suitable mandrel to press the bearing onto the forward gear until seated. Press only on the inner race of the bearing.
a a - Mandrel
b - Wood block
35614

87 Inside diameter of the forward gear tapered bearing 92-858064K01
Lubricant
7. Install the retaining ring into the groove of the forward gear, if equipped. Verify the retaining ring is seated in the groove.
a - Retaining ring
a
39701
Forward Gear Bearing Race Assembly

1. Place shims retained from disassembly into the housing. If shims were lost, or new components are used for reassembly,
start with a 0.762 mm (0.030 in.) shim.
2. Apply 24C with PTFE to the outside diameter of the forward gear bearing race.
3. Install the forward gear bearing race into the gear housing.
4. Install the bearing cup driver and pilot ring onto the bearing cup/adapter installation tool.
5. Install the installation tool into the gear housing. Verify the pilot ring is seated on the gearcase ledge.
6. Thread the retainer installer tool of the installation tool into the gearcase bearing carrier retainer threads and install the
driver screw into the retainer installer tool.
90-8M0082471 JULY 2014 Page 6A-35

7. Secure the retainer installer tool and thread the driver screw in until the forward gear bearing race is seated in the gear
housing.
c d a- Driver screw
a b b- Retainer installer tool (8M0074757)
c- Installation tool
d- Pilot ring (8M0074763)
e- Bearing cup driver
f- Bearing race
g- Shims
e g
f
49534

Pilot Ring 918M0074763

95 2-4-C with PTFE Outside diameter of forward gear bearing race 92-802859A 1
Driveshaft Assembly
1. Lubricate the inside diameter of the driveshaft tapered bearing with High Performance Gear Lubricant.
2. Thread a used pinion nut onto the driveshaft and leave approximately 2 mm (0.079 in.) of nut threads exposed. The
driveshaft threads must not extend beyond the nut or thread damage may result.
3. Install the lower bearing onto the driveshaft with the small diameter of the bearing towards the pinion nut end of the
driveshaft
4. Use the driveshaft bearing installation tool to press on the inner bearing race only until the bearing is seated on the
driveshaft.
a- Used pinion nut

a b- Driveshaft
c- Bearing
d- Driveshaft bearing installation tool
b e- Washer (obtain locally)
e
48776

87 Inside diameter of driveshaft tapered bearing 92-858064K01
Lubricant

5. Lubricate the inside diameter of the upper driveshaft tapered bearing with High Performance Gear Lubricant.
Page 6A-36 90-8M0082471 JULY 2014

6. Install the upper bearing onto the driveshaft with the large outside diameter of the bearing facing the pinion gear end of the
driveshaft.
7. Press the upper bearing onto the driveshaft with the driveshaft bearing installation tool.
a- Pinion nut
b- Driveshaft
a c- Lower driveshaft tapered bearing
d- Upper driveshaft tapered bearing
e- Driveshaft bearing installation tool
b f- Flat washer (obtain locally)
c
d e
f
48778

87 Inside diameter of upper driveshaft tapered bearing 92-858064K01
Lubricant

8. Install the shims and lower driveshaft bearing cup into the gear housing.
9. Install the forward gear into the gear housing.
10. Position the pinion gear into the gear housing with the teeth of the pinion gear meshed with the forward gear.
11. Insert the driveshaft while holding the pinion gear. Rotate the driveshaft to align and engage the driveshaft splines with the
pinion gear splines.
IMPORTANT: Do not apply Loctite 271 Threadlocker to the threads on the driveshaft until after the gear backlash has been
checked.
NOTE: After the shimming process is completed, a new pinion nut must be installed. Clean the pinion nut threads with
Loctite 7649 Primer N before applying Loctite 271 Threadlocker.

12. After the shimming process of the gearcase is completed, place a small amount of Loctite 271 Threadlocker onto the
threads of the pinion nut.

13. Install the flat washer and pinion nut onto the driveshaft with the flat side of the nut facing away from the pinion gear.
Handtighten the pinion nut.
14. Place the upper driveshaft shims retained from the disassembly into the gear housing.
90-8M0082471 JULY 2014 Page 6A-37

IMPORTANT: If the shims were lost or damaged, start with:
0.508 mm (0.020 in.) shim for the lower bearing
0.711 mm (0.028 in.) shim for the upper bearing
a a- Driveshaft
b- Pinion gear
g c- Washer
d- Pinion nut
f
e- Forward gear
f- Lower bearing shim
g- Upper bearing shim
e
b
c
d 56244

7 Loctite 271 Threadlocker Pinion nut threads 92-809819
15. Lubricate the bearing retainer with 24C with PTFE.

95 2-4-C with PTFE Bearing retainer 92-802859A 1
16. Install the upper driveshaft bearing race and secure the bearing with the bearing retainer.
17. Tighten the bearing retainer with the driveshaft bearing retainer wrench to the specified torque.
a- Driveshaft bearing retainer wrench

b- Bearing retainer
c- Upper bearing race
a d- Upper bearing shim
e- Lower bearing race
b
c
d
e
f 49267

Bearing retainer 135.5 100

Page 6A-38 90-8M0082471 JULY 2014

19. Use a socket and breaker bar to hold the pinion nut. Protect the area where the breaker bar will contact the gear housing
and tighten the pinion nut to the specified torque.
c a- Driveshaft holding tool

b- Torque wrench
c- Socket
b d- Breaker bar
a
a
d 48797

Pinion nut 101.7 75
20. Remove the pinion nut holding tool and the driveshaft holding tool.
21. Check the driveshaft rolling torque. Units correctly assembled to this point should be within the specified torque range. If
the driveshaft rolling torque is not within specification, the shim under the lower tapered roller bearing cup will need to be
changed and the driveshaft rolling torque rechecked. If the driveshaft rolling torque is too high, remove shims under the
lower bearing cup. If the driveshaft rolling torque is too low, add shims from under the lower bearing cup.

Driveshaft rolling torque 0.451.13 410
Pinion Gear Depth

IMPORTANT: The forward gear assembly pilots the end of the pinion gauge and must be installed in the gear housing when
checking pinion gear depth. An inaccurate measurement will be obtained without the forward gear assembly installed.
IMPORTANT: Do not assemble the propeller shaft until after the pinion gear depth and forward gear backlash are within
specifications.
IMPORTANT: The preload tool is not required to check pinion gear depth when the gear housing is assembled with new
bearings.
The preload tool must be used to check pinion gear depth when the gear housing is assembled with used bearings.
NOTE: Read the entire procedure before attempting any change in shim thickness.
1. Ensure the gear housing is clear of debris in the bearing carrier area.
90-8M0082471 JULY 2014 Page 6A-39

2. Position the gear housing with the driveshaft in a vertical position. Install the bearing preload tool with the correct sleeve
over the driveshaft in the sequence shown. Ensure the holes in the sleeve are in alignment with the set screws. Tighten the
set screws securely.
d a- Coupler
b- Threaded rod
c- Sleeve 22 mm (7/8 in.)
c e d- Sleeve 19 mm (3/4 in.)
e- Split sleeve 16 mm (5/8 in.)
f- Set screw (2)
f g- Bolt
g h- Spring
m i- Thrust washer
h j- Thrust bearing
b k- Adapter
i l- Plate
j m- Nut
a k
l
13288

3. Measure the distance between the top of the nut and the bottom of the bolt head.
4. Increase this distance by 25.4 mm (1 in.).
5. Rotate the driveshaft 510 revolutions to seat the driveshaft tapered roller bearing.
a a - Bolt head
b - Nut
c - Measure distance, then increase by 25.4 mm (1 in.)
7275
6. Assemble the pinion gear locating tool, as shown.
a. Install the gauging block with the numbers towards the arbor handle.
b. Position the split collar and gauging block against the pinion gauge adapter tool. Tighten the split collar retaining
screw.
c. Place the adapter tool on the arbor handle with side B toward the forward gear.
d a- Arbor handle
e
2 b- Screw (2)
3
c 1 c- Gauging block
8 4 d- Split collar
7 5
e- Split collar retaining screw
f- Pinion gauge adapter tool (8M0070993)
6
a f
b Side B toward the forward gear
b 48984
Page 6A-40 90-8M0082471 JULY 2014


NOTE: The pinion gear locating tool 9112349A05 may be used to determine pinion depth if a pinion gauge adapter tool is
installed on the end of the arbor allowing it to properly match with the forward gear bearing diameter. The part number for
the pinion gear location tool upgrade kit is 918M0089165. This kit includes a pinion gauge adapter tool and a #4 and #5
locating disc.
7. Insert the pinion gear locating tool into the forward gear assembly. Position the correct gauging block flat number under the
pinion gear, as shown.
a - Gauging block
a
7279
Model Gear Ratio (Pinion Gear Teeth/Reverse Gear Teeth) Use Flat Number Locating Disc Number
75115 EFI 2.1L 2.07:1 (14/29 teeth) 4 5
8. Install the locating disc against the bearing carrier shoulder in the gear housing.
9. Position the access hole, as shown.
a - Locating disc #5
a b - Access hole
b
7282
Locating Disc #5 918M0074768

10. Determine the pinion gear depth by inserting a feeler gauge through the access hole in the locating disc.
11. The correct clearance between the gauging block and the pinion gear is 0.64 mm (0.025 in.).
NOTE: Measure the pinion clearance at three locations 120 apart. Add the measurements and divide by three. This is the
average clearance of the pinion gear.
12. If the clearance is more than 0.64 mm (0.025 in.), remove shims under the upper driveshaft bearing race. If the clearance
is less than 0.64 mm (0.025 in.), add shims under the upper driveshaft bearing race.
NOTE: Changing the shims under the upper driveshaft bearing race will affect the driveshaft rolling torque. Check the
rolling torque after making any changes to the shims.
90-8M0082471 JULY 2014 Page 6A-41

13. Check the pinion gear depth after making a change to the pinion gear shimming.
d a- Feeler gauge
c a b- Gauging block
c- Pinion gear
d- Pinion bearing race
7283
14. If the clearance is correct, leave the bearing preload tool on the driveshaft and proceed to Forward Gear Backlash.
Forward Gear Backlash

1. Insert the propeller shaft assembly into the bearing carrier assembly.
NOTE: Do not install the shift cam into the cam follower.
2. Insert the bearing carrier into the gear housing and thread the bearing carrier retainer tightly against the bearing carrier. It
is not necessary to torque the bearing carrier retainer against the bearing carrier.
3. Install the puller jaws assembly onto the gear housing.
4. Tighten the puller bolt to the specified torque.
a d a- Propeller shaft
b
b- Bearing carrier
c- Bearing carrier retainer
d- Puller jaws assembly
e- Puller bolt
e
c
35631

Puller bolt 8.5 75
5. Install the threaded rod onto the gear housing.
6. Install the backlash indicator rod and dial indicator as shown.
c
b a- Backlash indicator rod
b- Plunger extension
c- Dial indicator adapter
d- Dial indicator
e- Threaded rod
d
e
56195
Page 6A-42 90-8M0082471 JULY 2014


7. Align the dial indicator with the appropriate line on the backlash indicator rod. Ensure the dial indicator is perpendicular to
the backlash indicator or an inaccurate reading will be obtained.
NOTE: Backlash indicator 918M0053505 utilizing line number one may also be used for checking forward gear backlash.
Backlash Indicator Tool Mark

Ratio Indicator number
2.07:1 (14 teeth pinion gear) 4
8. Lightly rotate the driveshaft backandforth. No movement should be noticed at the propeller shaft.
9. The dial indicator registers the amount of backlash. Ensure the forward gear backlash is within the specifications.

0.3560.457 mm
2.07:1 (14/29)
(0.0140.018 in.)
10. If the backlash is less than the minimum specification, remove shims from in front of the forward gear bearing race. If the
backlash is more than the maximum specification, add shims in front of the forward gear bearing race.
NOTE: By adding or subtracting 0.025 mm (0.001 in.), the backlash will change approximately 0.025 mm (0.001 in.).
11. Remove the puller jaws assembly and the backlash indicator assembly.
12. Remove the bearing carrier and propeller shaft assembly.
Propeller Shaft Assembly

1. Install the clutch onto the propeller shaft while aligning the cross pin hole in the clutch with the cross pin slot in the propeller
shaft.
a b c a- Propeller shaft
d b- Cross pin slot
c- Clutch reverse gear side
d- Cross pin hole
48407
2. Install the cam follower onto the actuator rod end.
a b a - Actuator rod
b - Cam follower
55946
90-8M0082471 JULY 2014 Page 6A-43

3. Align the cross pin opening in the actuator rod with the cross pin hole in the clutch. Insert the clutch actuator rod assembly
into the end of the propeller shaft. Position the actuator rod far enough into the propeller shaft to align the hole in the
actuator rod with the cross pin hole in the clutch.
c a- Propeller shaft
b- Clutch
c- Cross pin hole
d- Actuator rod
e- Cam follower
f- Cross pin
a d e
b
f
55939
4. Install the cross pin retaining spring. Do not allow the spring coils to overlap each other.
a b a - Clutch
b - Cross pin retaining spring
c - Cross pin (hidden)
c
55940
5. Lubricate the pocket on the cam follower with 24C with PTFE. This will help retain the shift cam onto the cam follower.
6. Install the shift cam as shown.
a b a - Shift cam
b - Cam follower
55941

95 2-4-C with PTFE Cam follower pocket 92-802859A 1
7. Verify that the clutch is in the neutral position and carefully install the propeller shaft assembly into the forward gear inside
the gear housing.
8. Apply Perfect Seal to the outside diameter of the shift shaft seal and install the seal into the shift shaft bushing with the seal
lip facing up towards the powerhead.
9. Install the Oring onto the shift shaft bushing and lubricate the Oring and seal lip with 24C with PTFE.
Page 6A-44 90-8M0082471 JULY 2014

NOTE: If difficulty is experienced installing the shift shaft bushing into the gear housing, remove the Oring from the shift
shaft bushing and install the Oring into the shift shaft bushing bore in the gear housing and then install the shift shaft
bushing/shift shaft assembly into the gear housing.
95 a - Shift shaft seal

b - Bushing
c - Oring
a
19
b
c
95
48440

95 2-4-C with PTFE Shift shaft bushing O-ring and seal lip 92-802859A 1
10. Install the shift shaft bushing onto the Ering end of the shift shaft.
11. Insert the shift shaft into the gear housing and into the shift cam. It may be necessary to rotate the shift shaft slightly for the
shift shaft splines to align with the shift cam.
a
a- Seal
b c- Oring
d- Ering
c e- Shift shaft
d f- Shift shaft access hole
48449
12. Install the rubber washer over the shift shaft onto the bushing.
90-8M0082471 JULY 2014 Page 6A-45

13. Secure the shift shaft bushing into the gear housing with a retaining ring.
a- Shift shaft
a
c- Rubber washer
b d- Retaining ring
d
c
55954
14. Install the Oring onto the bearing carrier. Lubricate the Oring with 24C with PTFE.
15. Apply 24C with PTFE to the outside diameter of the bearing carrier.
95 a - Oring
b - Thrust washer
a b
95
49030

95 2-4-C with PTFE O-ring and outside diameter of bearing carrier 92-802859A 1
16. Install the bearing carrier into the gear housing.
17. Install the keyed tab washer.
a. Position index tab B into the gear housing.
Page 6A-46 90-8M0082471 JULY 2014

b. Position index tab C into the bearing carrier.
a- Keyed washer
b a
b- Index tab
c- Index tab
d- Locking tab
c
d
d
56250
18. Lubricate the threads of the retainer nut with 24C with PTFE and install the retainer nut. Tighten the retainer nut to the
specified torque with the bearing carrier retainer nut wrench.
a- Oring
b- Retainer nut
c- Bearing carrier retainer nut wrench
d- Torque wrench
a b c d
95
48512

95 2-4-C with PTFE Threads of the retainer nut 92-802859A 1

Retainer nut 285 210

19. Bend the tab washer into the retainer nut.
20. Bend the remaining tabs of the tab washer toward the front of the gear housing.
NOTE: Replace the propeller bore sleeve if the sleeve is excessively worn or the retention tabs are broken.
90-8M0082471 JULY 2014 Page 6A-47

21. After all backlash measurements are correct, ensure the propeller bore sleeve is installed on the bearing carrier retainer
nut. Failure to install the propeller bore sleeve will result in a loss of boat performance.
a - Propeller bore sleeve

a
48534
Reverse Gear Backlash (Standard Rotation)

Reverse gear backlash is not adjustable. If reverse gear backlash is not within specification, the gearcase is not properly
assembled or the parts are excessively worn and must be replaced.
1. Shift the gearcase into reverse.
2. Install a 152.5 x 38.0 mm (6.0 x 1.5 in. inside diameter) PVC pipe over the propeller shaft and position the pipe against the
bearing carrier.
3. Secure the pipe against the bearing carrier with the propeller nut and tab washer. Tighten the propeller nut to the specified
torque.
a - PVC pipe
b - Propeller nut
c - Tab washer
a
b
48513

Propeller nut 5.5 49
4. Install the coupler and threaded rod onto the gear housing stud.
Page 6A-48 90-8M0082471 JULY 2014

c
d- Dial indicator
e- Threaded rod
d
e
56195

6. Align the dial indicator with the appropriate line on the backlash indicator tool. Ensure the dial indicator is perpendicular to
the indicator tool or an inaccurate reading will be obtained.

8. The dial indicator registers the amount of backlash. Ensure that the reverse gear backlash is within the specifications.
Reverse Gear Backlash

0.4060.965 mm
2.07: (14/29) Standard rotation
(0.0160.038 in.)
Water Pump Assembly

IMPORTANT: If the oil seals within the oil seal carrier require replacement, the oil seal carrier must be replaced as an
assembly.
NOTE: The filler block is a press fit. No adhesive is required.
1. Inspect the filler block for damage. Replace the filler block as required.
2. Apply 24C with PTFE to the seal lips and the oil seal carrier Oring.
a a - Oil seal carrier (oil seals are inside of the carrier)

b - Oring
c - Filler block
b
c
48519
90-8M0082471 JULY 2014 Page 6A-49


95 2-4-C with PTFE Oil seal carrier O-ring and seal lips 92-802859A 1
3. Install the oil seal carrier over the driveshaft and seat the carrier into the gearcase housing.
4. Secure the oil seal carrier assembly with a retaining ring.

b - Retaining ring
48281
NOTE: The faceplate may be reused if there are no other grooves other than the impeller sealing ring groove.
5. Install the faceplate over the driveshaft and onto the gear housing.
6. Install the drive key and impeller.
IMPORTANT: If the old impeller is being reused, do not install the impeller in reverse rotation to its original set. Premature
a - Impeller
b - Drive key
c - Faceplate with molded gasket
a
c b
55950
7. If the old pump cover is being reused, inspect the interior surface of the cover for grooves in excess of 0.762 mm
(0.030 in.). The impeller sealing groove is normal. Replace the cover as required.
8. Apply a light coat of 24C with PTFE to the inside of the water pump cover. Install the water pump cover over the
driveshaft and while turning the driveshaft in a clockwise direction, press the water pump cover over the water pump
impeller.
9. Secure the water pump cover with four screws. Tighten the screws to the specified torque.
10. Install the water tube coupler onto the water pump cover.
Page 6A-50 90-8M0082471 JULY 2014

11. Install the Vring face seal over the driveshaft. Use the Vring installation tool, supplied with the water pump kit, to seat the
Vring face seal against the water pump cover at the proper height.
a- Water tube coupler

b- Vring face seal
c- Water pump cover
a b c d- Screws (M6 x 20) (2 each side)
d
55949

95 2-4-C with PTFE Inside of water pump cover 92-802859A 1

Water pump cover screw (M6 x 20) (4) 6.8 60
Gear Housing Pressure Test

NOTE: The gear housing should be pressure tested for leaks after assembly and before the gear lubricant is added. The gear
housing should hold 103.4 kPa (15 psi) for fifteen minutes.
1. Remove the vent plug and install a pressure test gauge. Pressurize housing to 103.4 kPa (15 psi) and observe the gauge
for 15 minutes.
48537
2. Rotate the driveshaft, propeller shaft, and shift shaft while the housing is pressurized to check for leaks.
3. If a pressure drop is noted, immerse the housing in water.
4. Pressurize the gear housing to 103.4 kPa (15 psi) and check for air bubbles.
5. Replace any leaking seals. Retest the housing after seal replacement.
Gear Housing Test Pressure

Applied air pressure 103.4 kPa (15 psi)
Length of time 15 minutes
90-8M0082471 JULY 2014 Page 6A-51

6. Remove the tester from the housing and install the vent plug and sealing washer.
Gear Housing Installation

1. Tilt the engine to the full up position and engage the tilt lock lever.
2. Inspect the driveshaft housing to ensure that the water tube, mounting studs, and mating surfaces are clean.
55958
3. Lubricate the driveshaft splines with Engine Coupler Spline Grease.
NOTICE
Installing the gear housing to the powerhead without adequately cleaning the top of the driveshaft can result in severe
product damage. Any lubricant trapped in the space between the driveshaft and the crankshaft prevent the two from properly
engaging. Always clean the top of the driveshaft before installing the gear housing.
4. Lubricate the shift shaft splines with Engine Coupler Spline Grease.
5. Insert the trim tab/anodic plate screw into the gear housing.
6. Shift the gear housing into forward gear and place the shift block into the forward gear position.
a a - Reverse gear position

b - Neutral detent position
b c - Shift block in the forward gear position
c
55962

Grease
7. Position the gear housing so the driveshaft is protruding into the driveshaft housing.
8. Move the gear housing up into the driveshaft housing while aligning the upper shift shaft with the lower shift shaft, the
water tube with the water tube coupler, and the driveshaft splines with the crankshaft splines.
9. Place flat washers onto the studs located on either side of the driveshaft housing.
Page 6A-52 90-8M0082471 JULY 2014

10. Engage a locknut onto these studs fingertight.
48245
11. Thread the screw inside the trim tab/anodic plate recess into the driveshaft housing. Do not tighten the screw at this time.
a - Screw (M12 x 35)
48236
12. Check the shift shaft spline engagement and correct if necessary.
13. Alternately tighten the locknuts until the gearcase contacts the driveshaft housing.
14. Check the shift operation before installing the remaining washers, locknuts, and screw.
a. Move the shift block into forward gear position while turning the propeller shaft.
b. Rotate the flywheel clockwise: the propeller shaft should rotate clockwise.
c. Move the shift block into neutral position.
d. The propeller shaft should rotate freely in either direction.
e. Move the shift block into reverse gear position.
f. Rotate the flywheel clockwise and the propeller shaft should rotate counterclockwise.
NOTE: If the shifting operation is not as described, the gear housing must be removed and the cause corrected.
15. Tighten all the locknuts and the screw to the specified torque.
16. Install the anode or steering torque tab (if equipped) and secure with the screw.
90-8M0082471 JULY 2014 Page 6A-53

17. Tighten the anode screw to the specified torque and install the rubber cover into the anode screw hole opening.
a a - Rubber cover
55957

Locknuts (M12 x 1.75) (4) 60 44
Screw (M12 x 35) 75 55
Anode screw (0.43714 x 1.75) 54 40
Gear Lubricant Filling Instructions

NOTE: The gear housing should be pressure tested prior to filling with lubricant. Using Leakage Tester FT8950, the gear
housing should hold 103.4 kPa (15 psi) of pressure for 15 minutes without leakage. Failure to hold specified pressure indicates
worn or damaged sealing surfaces or improperly assembled gear housing. The cause of the leak must be corrected before
returning the gear housing assembly into service.

1. Inspect the fill and vent sealing washers for cuts or abrasions. Replace the washers if necessary.
IMPORTANT: Never add lubricant to gear housing without first removing the vent screw. Fill the gear housing only when
the housing is in a vertical position.
2. Slowly fill the gear housing through the fill hole with High Performance Gear Lubricant until lubricant flows out of the vent
hole and no air bubbles are visible.
3. Install the vent screw into the vent hole.
IMPORTANT: Do not lose more than 30 cc (1 fl oz) of gear lubricant while installing the fill screw.
Page 6A-54 90-8M0082471 JULY 2014

4. Remove the grease tube (or hose) from the fill hole and quickly install the fill screw into the fill hole. Torque the fill and vent
screws to the specified torque.
a - Fill screw
b - Vent screw
a
48252

87 Gear housing 92-858064K01
Lubricant

Fill and vent screws 11.3 100
90-8M0082471 JULY 2014 Page 6A-55

Notes:
Page 6A-56 90-8M0082471 JULY 2014

Command Thrust Right-Hand Rotation Gear Housing
Gear Housing
Section 6B - Command Thrust Right-Hand Rotation Gear Housing
Table of Contents
Command Thrust RightHand Gear Housing Propeller Shaft Inspection and Disassembly................... 6B-25
Specifications................................................................. 6B-2 Propeller Shaft Inspection.........................................6B-25
Gear Housing Driveshaft Components.............................. 6B-8 Propeller Shaft Disassembly.....................................6B-26
Gear Housing (Command Thrust Propeller Shaft 2.38:1 Pinion Gear and Driveshaft Removal...............................6B-27
RightHand Rotation)....................................................6B-12 Driveshaft Cleaning and Inspection.......................... 6B-29
General Service Recommendations................................ 6B-14 Forward Gear Disassembly............................................. 6B-29
Bearings....................................................................6B-14 Cleaning and Inspection........................................... 6B-30
Shims........................................................................6B-14 Gear Housing Inspection................................................. 6B-31
Seals.........................................................................6B-14 Pinion Bearing Installation............................................... 6B-31
Gear Housing Removal ...................................................6B-14 Bearing Carrier Assembly................................................ 6B-32
Gearcase Service Inspection........................................... 6B-16 Forward Gear Assembly.................................................. 6B-35
Draining and Inspecting Gear Housing Lubricant..... 6B-16 Forward Gear Bearing Race Assembly........................... 6B-36
Propeller Shaft Inspection.........................................6B-16 Driveshaft Assembly........................................................ 6B-37
6
Water Pump Removal and Disassembly......................... 6B-17 Pinion Gear Depth........................................................... 6B-40
Cleaning and Inspection........................................... 6B-19 Forward Gear Backlash................................................... 6B-43
Oil Seal Carrier Assembly................................................6B-19 Propeller Shaft Assembly.................................................6B-44
Removal....................................................................6B-19
Disassembly............................................................. 6B-20
Reverse Gear Backlash (Standard Rotation)...................6B-49
Water Pump Assembly.................................................... 6B-49
B
Bearing Carrier and Propeller Shaft Removal .................6B-20 Gear Housing Pressure Test........................................... 6B-52
Shift Shaft Inspection................................................6B-23 Gear Housing Installation.................................................6B-52
Bearing Carrier Disassembly........................................... 6B-23 Gear Lubricant Filling Instructions................................... 6B-55
90-8M0082471 JULY 2014 Page 6B-1

Command Thrust RightHand Gear Housing Specifications

RightHand Gear Housing Specifications (Command Thrust)
Water pressure
At 5800 RPM (WOT) 80300 kPa (11.643.5 psi)

Outside diameter of outer propeller shaft oil seal
Pinion nut threads
Inside diameter of the reverse gear ball bearing
Outside diameter of the propeller shaft needle bearing
Outside diameter of the reverse gear ball bearing
High Performance Gear Center bore of the forward gear
87 92-858064K01
Lubricant Inside diameter of the forward gear tapered bearing
Inside diameter of driveshaft tapered bearing
Gear housing
Grease
Pinion bearing bore
Oil seal lips and O-ring
Outside diameter of forward gear bearing race
Bearing retainer
Pocket on the cam follower
95 2-4-C with PTFE 92-802859A 1
O-ring and outside diameter of bearing carrier
Oil seal carrier O-ring and seal lips
Special Tools

location, and TDC.
9479
Page 6B-2 90-8M0082471 JULY 2014

Dial indicator holding fixture

2999
Secures the dial indicator to gear housing when checking backlash
29496
46139
9514
6761
Removes bearings from gears and the driveshaft
8505
90-8M0082471 JULY 2014 Page 6B-3


Installs and removes the bearings in all gearcase. All components can be
9131229A 7 tool assembly includes the following components:
1124156 Hex Nut
1234961 Washer
9115755T Needle Bearing Driver
9129310 Plate
9130366T 1 Mandrel
9131229 Puller Shaft
9132336 Needle Bearing Driver
9136379 Puller and Head Gear
9137292 Roller Bearing
9137311 Driver Head
2966 9137323 Driver Head Rod
9137350T Pilot Mandrel
9138628T Puller and Driver Head
9152393T Pinion Bearing Installation Tool
9152394 Head Pull Rod
9520
28677
Driver Rod 9137323
25431 Aids in the removal and installation of various bearings and bearing races
Bearing Driver Tool 918M0062360
Removes pinion bearing from gear housing
49079
Pilot Washer 9136571T
Used in pinion gear and pinion bearing installation
29490
Page 6B-4 90-8M0082471 JULY 2014

Installs needle bearings into bearing carriers
10787
Installs bearing carrier oil seals
8883
Torch Lamp 9163209
Heats surfaces to aid in the removal and installation of interference fit engine
components
8776
Mandrel 918M0039811
Install needle bearing into forward gear
48574
lefthand gear case
49525
Installer Pilot 918M0048035
Maintains the alignment of the driver tool
49523
90-8M0082471 JULY 2014 Page 6B-5

49263
Bearing Cup Driver 9187120T
Installs the forward gear bearing cup

9445
47416
measurements
8756
2
3
1
4
8
7 5
6
56235
56254
Page 6B-6 90-8M0082471 JULY 2014

Locating Disc 918M0060656
Provides access hole to measure pinion depth
49549

9450

47536
Used for pressure testing of closed systems (gearcase, fuel lines, cooling).
29497
90-8M0082471 JULY 2014 Page 6B-7


20
19
20
21
22 23
24
25
26
27
18
12 11
28
29
30
13 31
32
14 38 33
15 34
39
16 35
40
17 36
41
9
5
37
7
6
4
6
8
2 10
3
1
55146
Page 6B-8 90-8M0082471 JULY 2014


Torque
2 2 Vent screw 11.3 100
3 4 Seal
4 1 Dowel pin
6 2 Anode
7 1 Screw (M6 x 40) 6.8 60
8 1 Nut (M6)
9 1 Screw (0.43714 x 1.750) 54 40
10 1 Trim tab anode
12 1 Ering
13 1 Retaining ring
14 2 Washer
15 1 Oil seal
17 1 Oring
18 1 Driveshaft
20 2 Oring
21 4 Screw (M6 x 20) 6.8 60
22 1 Face seal
23 1 Filler block
25 1 Key
27 1 Faceplate
28 1 Retaining ring
31 1 Oring
32 1 Retainer 135.5 100
34 1 Tapered roller bearing assembly
35 1 Shim
37 1 Shim set
38 1 Needle bearing
40 1 Washer
90-8M0082471 JULY 2014 Page 6B-9

Torque
41 1 Nut (0.62518) 67.8 50
Page 6B-10 90-8M0082471 JULY 2014


20
19
20
21
22 23
24
25
26
27
18
12 11
28
29
30
13 31
32
14 38 33
15 34
39
16 35
40
17 36
41
9
5
37
7
6
4
6
8
2 10
3
1
55146
90-8M0082471 JULY 2014 Page 6B-11

Gear Housing (Command Thrust Propeller Shaft 2.38:1 RightHand Rotation)
14
11
13
12
2
3 27
10 4
5 26
6
25
7
8 24
9 23
20
19
18 21
17 22
16
15
55147
Page 6B-12 90-8M0082471 JULY 2014

Gear Housing (Command Thrust Propeller Shaft 2.38:1 Right-Hand Rotation)

Torque
1 1 Gearcase
3 1 Needle bearing
4 1 Retaining ring
5 1 Tapered roller bearing cone (1.9685 I.D.)
6 1 Tapered roller bearing cup (3.5433 O.D.)
7 1 Shim
9 1 Cam follower
10 1 Shift cam
11 1 Six jaw sliding clutch
12 1 Cross pin
13 1 Retaining spring
16 1 Ball bearing
17 1 Thrust ring
18 1 Oring (3.975 x 0.210)
19 1 Bearing carrier
20 1 Needle bearing
21 1 Fill screw 11.3 100
22 1 Seal
23 1 Oil seal
24 1 Seal
25 1 Tab washer
26 1 Retainer 285 210
90-8M0082471 JULY 2014 Page 6B-13


There may be more than one way to disassemble or assemble a particular part. It is recommended the entire procedure be
Service procedure order in this section is a normal disassembly/assembly sequence. The sequence should be followed without
deviation to assure proper repairs. When performing partial repairs, follow the instructions to the point where the desired
component can be replaced, then proceed to assembly and installation of that component in the assembly part of this section.
Use the Table of Contents to find the correct page number.
Bearings
be replaced.
Shims
Keep a record of all shim amounts and their location during disassembly to aid in assembly. Be sure to follow the shimming
instructions during assembly, as gears must be installed to the correct depth and have the correct amount of backlash to avoid
noisy operation and premature gear failure.
Seals

! WARNING

Page 6B-14 90-8M0082471 JULY 2014

b a- Tab washer
f
d- Rear thrust hub
e- Propeller shaft
f- Front thrust hub
d c e
48808
a a - Rubber cover
55957
a - Screw
48236
90-8M0082471 JULY 2014 Page 6B-15

48245

a - Fill screw
b - Vent screw
a
48252

Page 6B-16 90-8M0082471 JULY 2014

3. Push in and pull out on the propeller shaft to determine propeller shaft end play. Propeller shaft end play should be
0.1271.905 mm (0.0050.075 in.). If the propeller shaft end play is not within specification, the gearcase should be
disassembled for inspection.

d c- Dial indicator
3234
Propeller Shaft
Runout 0.152 mm (0.006 in.)
End play 0.1271.905 mm (0.0050.075 in.)


1. Remove the shift shaft rubber washer.
a - Shift shaft rubber washer
48582
90-8M0082471 JULY 2014 Page 6B-17

a - Vring face seal

b - Water pump cover
c - Screws (M6 x 20) (2 each side)
a
b
c 48265

a a - Impeller
b - Drive key
48268
7. Remove the water pump face plate and both gaskets from the gear housing.
a
a - Fiber gasket (gray neoprene strip faces up)
b - Face plate
c - Metal gasket
48269
Page 6B-18 90-8M0082471 JULY 2014


1. Inspect the face plate and water pump liner for grooves or rough surfaces.
2. Inspect the stainless steel gasket coated surface for scratches or damage. If the coating is scratched or damaged, replace
the stainless steel gasket.
a - Stainless steel gasket

a
b - Coating
b
46007
4. Inspect the impeller bonding to the impeller hub.
b a
a - Impeller
b - Hub
28496

Removal

b - Retaining ring
48281
90-8M0082471 JULY 2014 Page 6B-19


c - Protective pad
a
c
b
48284

b - Oring
48291
Disassembly

Page 6B-20 90-8M0082471 JULY 2014

a - Retainer nut
c - Lock tabs
a
b
c
48306
4. Remove the gear housing retainer nut and propeller bore sleeve with the bearing carrier retainer nut wrench.

a
55955

48311
6. Verify that the gear housing is in neutral. Remove the shift shaft bushing retaining ring.
90-8M0082471 JULY 2014 Page 6B-21

a - Shift shaft
a b - Shift shaft bushing
c - Retaining ring
b
48315

a
48317
Page 6B-22 90-8M0082471 JULY 2014

d
a
b
48555
a- Long jaws
b- Puller bolt
c- Thrust hub
e- Shift shaft



1. Remove and discard the Oring on the bearing carrier.
2. Secure the bearing carrier in a soft jaw vise.
IMPORTANT: Clamp on the raised reinforcing rib on the bearing carrier when securing the carrier in a vise to prevent
damage to the carrier.
90-8M0082471 JULY 2014 Page 6B-23

3. Use a slide hammer to remove the reverse gear assembly.
e a- Bearing carrier
c b- Oring
b d c- Spacer
d- Reverse gear
e- Slide hammer
a
f- Raised reinforcing rib
48321
f
4. Use the universal puller plate and a suitable mandrel to press the gear off the bearing.
5. If the reverse gear bearing remained in the bearing carrier, use the slide hammer to remove the bearing.

b- Bearing
c- Gear
d d- Mandrel
b
c
33975

6. Inspect the reverse gear to pinion gear wear pattern. It should be even and smooth. If not, replace the reverse gear, pinion
gear, and forward gear.
7. Inspect the reverse gear for pitted, chipped or broken teeth, and hairline fractures. Replace the reverse gear and the pinion
gear if any defects are found.
Page 6B-24 90-8M0082471 JULY 2014

8. Check the clutch jaws on the reverse gear for damage. Replace the reverse gear if damage is found.
b a - Reverse gear
b - Clutch jaws
a
49529
9. Remove the propeller shaft oil seals with a pry bar or slide hammer.
NOTE: Do not damage the inside diameter of the bearing carrier when removing the propeller shaft seals.
10. Press the propeller shaft needle bearing out of the bearing carrier with a suitable mandrel.
d 35535
a- Pry bar
b- Propeller shaft needle bearing
c- Mandrel
d- Oil seals

2. Inspect the propeller shaft bearing carrier oil seal surface area for grooves. Replace the shaft if grooves are found.
3. Inspect the bearing surfaces of the propeller shaft for pitting, grooves, scoring, uneven wear, or discoloration from
overheating. Replace the shaft and corresponding needle bearing if any of the previous mentioned conditions are found.
90-8M0082471 JULY 2014 Page 6B-25

Position the propeller shaft roller bearing surfaces on Vblocks. Use a dial indicator at the front edge of the propeller
splines. Rotate the propeller shaft. Dial indicator movement more than the specification requires the propeller shaft to
be replaced.
a - Vblocks
b - Bearing surfaces
c - Dial indicator location
b
b
a
c
48396
Propeller Shaft
Runout 0.152 mm (0.006 in.)

5. Inspect the propeller shaft splines for wear or corrosion damage.
6. Inspect the sliding clutch jaws. Rounded clutch jaws indicate one or more of the following conditions:
Improper shift cable adjustment
Improper shifting technique shifting too slow
Engine RPM too high while shifting
a a - Reverse gear clutch dog teeth

b
b - Forward gear clutch dog teeth
55625

1. Remove the shift cam from the cam follower.
2. Insert a thin blade screwdriver or awl under the first coil of the retaining spring and rotate the propeller shaft to unwind the
spring from the clutch. Do not overstretch the spring.
a a - Cross pin retaining spring

b - Awl
c - Shift cam
c
b 55617
Page 6B-26 90-8M0082471 JULY 2014

3. Push the cross pin out of the sliding clutch and propeller shaft.
a - Cross pin
a
55618
a- Sliding clutch
b- Cross pin
c- Propeller shaft
d- Clutch actuator rod
e- Cam follower
a d e
c
b
55619
5. Remove the sliding clutch from the propeller shaft.

6. Clean the clutch actuator rod and cam follower in a mild solvent. Dry with compressed air and inspect the components for
wear or damage.

48340


90-8M0082471 JULY 2014 Page 6B-27

driveshaft.
the 18 rollers.
a - Wood block
b a
48341
covers.
a - Upper bearings
a
56202

16. Install the bearing driver tool into the pinion bearing and insert the driver rod into the gearcase and mandrel.
17. Install the pilot washer over the driver rod and into the gear housing to align the removal tools.
Page 6B-28 90-8M0082471 JULY 2014

a - Bearing driver tool

b - Pilot washer
c - Driver rod
48344
Driver Rod 9137323


! WARNING
b a - Splines
a c a
56198
Forward Gear Disassembly

2. Place the forward gear, with the teeth side up, into a soft jaw vise.
90-8M0082471 JULY 2014 Page 6B-29

3. Use a punch and hammer to remove the propeller shaft needle bearing and discard the bearing.
b 35566
a - Retaining ring
b - Bearing
4. Install the universal puller plate between the forward gear and tapered bearing.
5. Press the gear out of the bearing with a suitable mandrel. Discard the bearing.
6. Remove the forward gear tapered bearing race from the gear housing with a slide hammer and retain the shims that are
behind the forward gear tapered bearing race.
b
c
a
d 35562

b- Mandrel
c- Slide hammer
d- Tapered bearing race


1. Clean all parts with a mild solvent and dry with compressed air. Do not spin the bearings.
! WARNING
Page 6B-30 90-8M0082471 JULY 2014

3. Inspect the clutch dogs for damage. Replace the gear if damage is found.

a
49365
holes.

2. Install the pinion bearing onto the mandrel so the letter and number side of the bearing is facing up.
3. Insert the mandrel and bearing into the gear housing pinion bearing bore.
4. Install the puller plate onto the puller rod and insert the puller rod into the gear housing driveshaft bore. Thread the puller
rod into the mandrel.
90-8M0082471 JULY 2014 Page 6B-31

5. Secure the puller rod and tighten the nut until the mandrel contacts the gear housing.
a- Puller rod
b- Puller plate
a c- Pilot washer
d- Pinion bearing (letters/numbers face up)
f e- Mandrel
b f- Hex nut
e
48970

Bearing Carrier Assembly

1. Place the reverse gear on a press with the gear teeth facing down.
2. Place the thrust washer over the gear.
3. Apply High Performance Gear Lubricant onto the inside diameter of the reverse gear ball bearing and position the ball
bearing onto the gear with the numbered side of the bearing facing up.
b a - Thrust washer
b - Mandrel
39699

87 Inside diameter of the reverse gear ball bearing 92-858064K01
Lubricant
4. Press the ball bearing onto the gear with a suitable mandrel until seated. Press only on the inner race of the bearing.
5. Apply High Performance Gear Lubricant onto the outside diameter of the propeller shaft needle bearing and place the
propeller shaft needle bearing with the numbers facing aft, into the bearing carrier.
Page 6B-32 90-8M0082471 JULY 2014

6. Press the bearing into the bearing carrier with the needle bearing driver tool until the tool is seated on the bearing carrier.
a - Needle bearing driver tool
48403

87 Outside diameter of the propeller shaft needle bearing 92-858064K01
Lubricant

7. Install the first seal onto the long shoulder side of the oil seal driver. Verify the seal lip faces away from the mandrel
a - Oil seal
b b - Oil seal driver
48361

8. Apply Loctite 271 Threadlocker to the outside diameter of the second (outer) propeller shaft oil seal.
90-8M0082471 JULY 2014 Page 6B-33

9. Install the second seal onto the short shoulder side of the oil seal driver. Verify the seal lip faces towards the oil seal driver
b a - Oil seal
b - Oil seal driver
48398

7 Loctite 271 Threadlocker Outside diameter of outer propeller shaft oil seal 92-809819
10. Remove excess Loctite 271 Threadlocker from the seal area.
11. Apply High Performance Gear Lubricant onto the outside diameter of the reverse gear ball bearing.
12. Place the bearing carrier over the thrust washer and the reverse gear assembly.
NOTE: Warming the bearing carrier with a torch lamp where the reverse gear assembly resides will aid in the installation of
the reverse gear assembly.
13. Use a suitable mandrel to press the bearing carrier onto the bearing.
a - Mandrel
b - Bearing seated
a c - Thrust washer
c 56248

87 Outside diameter of the reverse gear ball bearing 92-858064K01
Lubricant
Torch Lamp 9163209

14. Install an Oring between the bearing carrier and thrust washer.
Page 6B-34 90-8M0082471 JULY 2014

15. Apply 24C with PTFE to the oil seal lips and Oring.
95 a- Oring
b- Thrust washer
c- Reverse gear
c d- Propeller shaft seals (hidden)
95
a b 48476

95 2-4-C with PTFE Oil seal lips and O-ring 92-802859A 1
Forward Gear Assembly

1. Apply High Performance Gear Lubricant into the center bore of the forward gear.
2. Install the numbered side of the forward gear needle bearing onto the short shoulder side of the forward gear bearing tool.
NOTE: The bearing carrier needle bearing contacts the propeller shaft in front of the oil seal area. The forward gear
bearing contacts the propeller shaft in front of the clutch splines.
3. Press the bearing into the forward gear until the mandrel is against the gear.
a - Mandrel
b - Bearing
c - Forward gear
a
b
c
48568

87 Center bore of the forward gear 92-858064K01
Lubricant
Mandrel 918M0039811
4. Place the forward gear on a press with the gear teeth facing down.
5. Apply High Performance Gear Lubricant to the inside diameter of the forward gear tapered bearing and position the
forward gear tapered bearing over the gear.
90-8M0082471 JULY 2014 Page 6B-35

6. Use a suitable mandrel to press the bearing onto the forward gear until seated. Press only on the inner race of the bearing.
a a - Mandrel
b - Wood block
35614

87 Inside diameter of the forward gear tapered bearing 92-858064K01
Lubricant
7. Install the retaining ring into the groove of the forward gear, if equipped. Verify the retaining ring is seated in the groove.
a - Retaining ring
a
39701
Forward Gear Bearing Race Assembly

1. Place shims retained from disassembly into the housing. If shims were lost, or new components are used for reassembly,
start with a 0.762 mm (0.030 in.) shim.
2. Apply 24C with PTFE to the outside diameter of the forward gear bearing race.
3. Install the forward gear bearing race into the gear housing.
4. Install the bearing cup driver and pilot ring onto the bearing cup/adapter installation tool.
5. Install the installation tool into the gear housing. Verify the pilot ring is seated on the gearcase ledge.
6. Thread the retainer installer tool of the installation tool into the gearcase bearing carrier retainer threads and install the
driver screw into the retainer installer tool.
Page 6B-36 90-8M0082471 JULY 2014

7. Secure the retainer installer tool and thread the driver screw in until the forward gear bearing race is seated in the gear
housing.
c d a- Driver screw
a b b- Retainer installer tool (8M0048109)
c- Installation tool
d- Pilot ring (8M0048035)
e- Bearing cup driver
f- Bearing race
g- Shims
e g
f
49534

Bearing Cup Driver 9187120T

95 2-4-C with PTFE Outside diameter of forward gear bearing race 92-802859A 1
Driveshaft Assembly
driveshaft
driveshaft.
a- Used pinion nut

a b- Driveshaft
c- Bearing
e
48776

Lubricant

90-8M0082471 JULY 2014 Page 6B-37

driveshaft.
a- Pinion nut
b- Driveshaft
c
d e
f
48778

Lubricant

checked.


Page 6B-38 90-8M0082471 JULY 2014

a a- Driveshaft
b- Pinion gear
g c- Washer
d- Pinion nut
f
e- Forward gear
e
b
c
d 56244



b- Bearing retainer
b
c
d
e
f 49267


90-8M0082471 JULY 2014 Page 6B-39


b- Torque wrench
c- Socket
b d- Breaker bar
a
a
d 48797

Pinion nut 67.8 50

Pinion Gear Depth

IMPORTANT: The reverse gear assembly pilots the end of the pinion gauge and must be installed in the gear housing when
specifications.
bearings.
Page 6B-40 90-8M0082471 JULY 2014

d a- Coupler
b- Threaded rod
f- Set screw (2)
f g- Bolt
g h- Spring
m i- Thrust washer
h j- Thrust bearing
b k- Adapter
i l- Plate
j m- Nut
a k
l
13288

a a - Bolt head
b - Nut
7275
screw.
c. Place the adapter tool on the arbor handle with side A toward the forward gear.
d a- Arbor handle
e
2 b- Screw (2)
3
8 4 d- Split collar
7 5
6
a f
b Side A toward the forward gear
b 48984
90-8M0082471 JULY 2014 Page 6B-41


NOTE: Pinion gear locating tool 9112349A05 may be used to determine pinion depth if a pinion gauge adapter tool is
locating disc.
NOTE: Pinion gear locating tool 918M0057712 and pinion gauge adapter tool 918M0060702 may be used to determine
pinion depth.
a - Gauging block
a
7279
2.1L Command Thrust 2.38:1 (13/31) 4 4
a b - Access hole
b
7282

Page 6B-42 90-8M0082471 JULY 2014

d a- Feeler gauge
c- Pinion gear
7283
15. Remove the preload tool.
16. Install the spacer shim into the gear housing.

1. Insert the propeller shaft assembly into the bearing carrier assembly.
NOTE: Do not install the shift cam into the cam follower.
2. Insert the bearing carrier into the gear housing and thread the retainer tightly against the bearing carrier. It is not necessary
to torque the retainer against the bearing carrier.
3. Install the puller jaws assembly onto the gear housing.
4. Tighten the puller bolt against the propeller shaft to the specified torque.
a d a- Propeller shaft
b
b- Bearing carrier
c- Bearing carrier retainer
d- Puller jaws assembly
e- Puller bolt
e
c
35631

Puller bolt 8.5 75
5. Install the threaded rod onto the gear housing.
90-8M0082471 JULY 2014 Page 6B-43

c
d- Dial indicator
e- Threaded rod
d
e
56195

the backlash indicator or an inaccurate reading will be obtained.
NOTE: Backlash indicator 918M0053505 utilizing line number one may also be used for checking forward gear backlash.


0.3560.483 mm
2.38:1 (13/31)
(0.0140.019 in.)
10. If the backlash is less than the minimum specification, remove shims from in front of the forward gear bearing race. If the
backlash is more than the maximum specification, add shims in front of the forward gear bearing race.
11. Remove the puller jaws assembly and the backlash indicator assembly.
12. Remove the bearing carrier and propeller shaft assembly.

1. Install the clutch onto the propeller shaft while aligning the cross pin hole in the clutch with the cross pin slot in the propeller
shaft.
a b c d a- Propeller shaft
b- Cross pin slot
c- Clutch
d- Cross pin hole
55699
Page 6B-44 90-8M0082471 JULY 2014

2. Install the cam follower onto the actuator rod end.
a b a - Actuator rod
b - Cam follower
55622
3. Align the cross pin opening in the actuator rod with the cross pin hole in the clutch. Insert the clutch actuator rod assembly
into the end of the propeller shaft. Position the actuator rod far enough into the propeller shaft to align the hole in the
actuator rod with the cross pin hole in the clutch.
a b c e
d a- Propeller shaft
b- Clutch
c- Cross pin hole
d- Actuator rod
e- Cam follower
f- Cross pin
f
55626
4. Install the retaining spring to retain the cross pin. Do not allow the spring coils to overlap each other.
a b a - Clutch
b - Cross pin (hidden)
c - Retaining spring
c
55630
6. Install the shift cam into the cam follower pocket as shown.
a - Shift cam
a b
b - Cam follower
55631
90-8M0082471 JULY 2014 Page 6B-45


95 2-4-C with PTFE Pocket on the cam follower 92-802859A 1
7. Verify that the clutch is in the neutral position and carefully install the propeller shaft assembly into the forward gear inside
the gear housing.

b - Bushing
c - Oring
a
19
b
c
95
48440

a
a- Seal
b c- Oring
d- Ering
c e- Shift shaft
48449
Page 6B-46 90-8M0082471 JULY 2014

a - Shift shaft
c - Retaining ring
b
48315
13. Install the Oring onto the bearing carrier. Lubricate the Oring with 24C with PTFE.
14. Apply 24C with PTFE to the outside diameter of the bearing carrier.
95 a - Oring
b - Thrust washer
a b
95
49030

95 2-4-C with PTFE O-ring and outside diameter of bearing carrier 92-802859A 1
15. Install the spacer onto the propeller shaft.
16. Install the bearing carrier into the gear housing.
90-8M0082471 JULY 2014 Page 6B-47

a- Keyed washer
b a
b- Index tab
c- Index tab
d- Locking tab
c
d
d
56250
a- Oring
b- Retainer nut
d- Torque wrench
a b c d
95
48512



19. Bend the tab washer into the retainer nut.
20. Bend the remaining tabs of the tab washer toward the front of the gear housing.
NOTE: Replace the propeller bore sleeve if the sleeve is excessively worn or the retention tabs are broken.
Page 6B-48 90-8M0082471 JULY 2014

21. After all backlash measurements are correct, ensure the propeller bore sleeve is installed on the bearing carrier retainer
nut. Failure to install the propeller bore sleeve will result in a loss of boat performance.

a
48534
Reverse Gear Backlash (Standard Rotation)

Reverse gear backlash is not adjustable and is not checked during the assembly process.
Water Pump Assembly

assembly.

b - Oring
c - Filler block
b
c
48519

95 2-4-C with PTFE Oil seal carrier O-ring and seal lips 92-802859A 1
90-8M0082471 JULY 2014 Page 6B-49


b - Retaining ring
48281
NOTE: The metal gasket may be reused if the black surface is not scratched or damaged. The face plate may be reused if
there are no other grooves other than the impeller sealing ring groove. The fiber gasket may be reused if there is no
damage to the gray neoprene strip or the fiber gasket itself.
5. Install a new metal gasket, face plate, and fiber gasket.
a
b - Face plate
c - Metal gasket
48269
Page 6B-50 90-8M0082471 JULY 2014

IMPORTANT: If the old impeller is being reused, do not install the impeller in reverse rotation to its original set. Premature
a a - Impeller
b - Drive key
48268
impeller.
9. Secure the water pump cover with four screws. Tighten the screws to specification.
10. Install the Vring face seal over the driveshaft. Use the Vring installation tool to seat the Vring face seal against the water
pump cover at the proper height.
a - Vring face seal

c - Screws (two each side)
a
b
c 48265


Water pump cover screw (4) 6.8 60
90-8M0082471 JULY 2014 Page 6B-51

11. Install the shift shaft rubber washer against the shift shaft seal.
48582

housing should hold 103.4 kPa (15 psi) for fifteen minutes.
1. Remove the vent plug and install a pressure test gauge. Pressurize housing to 103.4 kPa (15 psi) and observe the gauge
for 15 minutes.
48537


Gear Housing Installation

Page 6B-52 90-8M0082471 JULY 2014

55958
NOTICE

c
55962

Grease
90-8M0082471 JULY 2014 Page 6B-53

48245
48236
b. Rotate the flywheel clockwise: the propeller shaft should rotate clockwise.
f. Rotate the flywheel clockwise and the propeller shaft should rotate counterclockwise.
16. Install the anode or steering torque tab (if equipped) and secure with the screw.
Page 6B-54 90-8M0082471 JULY 2014

a a - Rubber cover
55957

Locknuts (M12 x 1.75) (4) 60 44
Screw (M12 x 35) 75 55
Anode screw (0.43714 x 1.75) 54 40

housing should hold 103.4 kPa (15 psi) of pressure for 15 minutes without leakage. Failure to hold specified pressure indicates
worn or damaged sealing surfaces or improperly assembled gear housing. The cause of the leak must be corrected before
returning the gear housing assembly into service.

90-8M0082471 JULY 2014 Page 6B-55

a - Fill screw
b - Vent screw
a
48252

Lubricant

Page 6B-56 90-8M0082471 JULY 2014

Command Thrust Left-Hand Rotation Gear Housing
Gear Housing
Section 6C - Command Thrust Left-Hand Rotation Gear Housing
Table of Contents
Command Thrust LeftHand Gear Housing Specifications Propeller Shaft Disassembly.................................... 6C-25
....................................................................................... 6C-2 Forward Gear and Bearing Adapter Disassembly .......... 6C-26
Gear Housing Driveshaft Components.............................. 6C-8 Bearing Adapter Assembly....................................... 6C-28
Gear Housing (Propeller Shaft Command Thrust 2.38:1 Pinion Gear and Driveshaft Removal.............................. 6C-29
LeftHand Rotation)......................................................6C-12 Driveshaft Cleaning and Inspection..........................6C-31
General Service Recommendations................................ 6C-14 Reverse Gear Removal and Disassembly.......................6C-32
Bearings................................................................... 6C-14 Cleaning and Inspection........................................... 6C-32
Shims........................................................................6C-14 Gear Housing Inspection................................................. 6C-33
Seals.........................................................................6C-14 Pinion Bearing Installation............................................... 6C-34
Gear Housing Removal .................................................. 6C-14 Forward Gear Bearing Carrier Assembly.........................6C-35
Gearcase Service Inspection...........................................6C-16 Reverse Gear and Bearing Adapter Assembly ...............6C-36
Draining and Inspecting Gear Housing Lubricant.....6C-16 Reverse Gear Assembly...........................................6C-36
Propeller Shaft Inspection........................................ 6C-16 Bearing Adapter Assembly....................................... 6C-37
6
Water Pump Removal and Disassembly......................... 6C-17 Reverse Gear Bearing Adapter and Gear Installation..... 6C-37
Cleaning and Inspection........................................... 6C-19 Driveshaft Assembly........................................................ 6C-39
Oil Seal Carrier Assembly................................................6C-19 Pinion Gear Depth........................................................... 6C-42
Removal................................................................... 6C-19
Disassembly............................................................. 6C-20
Propeller Shaft Assembly................................................ 6C-45
Shift Shaft Installation...................................................... 6C-50
C
Bearing Carrier and Propeller Shaft Removal ................ 6C-20 Forward Gear Backlash................................................... 6C-52
Shift Shaft Inspection................................................6C-23 Water Pump Assembly.................................................... 6C-53
Bearing Carrier Disassembly........................................... 6C-23 Gear Housing Pressure Test........................................... 6C-56
Propeller Shaft Inspection and Disassembly................... 6C-24 Gear Housing Installation (LeftHand Rotation)...............6C-57
Propeller Shaft Inspection........................................ 6C-24 Gear Lubricant Filling Instructions................................... 6C-59
90-8M0082471 JULY 2014 Page 6C-1

Command Thrust LeftHand Gear Housing Specifications

LeftHand Gear Housing Specifications (Command Thrust)
Water pressure
At 5800 RPM (WOT) 80300 kPa (11.643.5 psi)

Outside diameter of the second propeller shaft oil seal
Pinion nut threads
Outside diameter of bearing cup
Outside diameter of propeller shaft needle bearing
Inside diameter of the bearing adapter and the outside diameter
High Performance Gear of the bearing
87 92-858064K01
Lubricant Inside diameter of driveshaft tapered bearing
Forward gear tapered roller bearings
Gear housing
Grease
Pinion bearing bore
Oil seal lips
Outside diameter of bearing adapter
Thrust washer and thrust bearing
Bearing retainer
Pocket on cam follower
95 2-4-C with PTFE Propeller shaft seal lips and the cavity between the seals 92-802859A 1
Bearing carrier O-ring
Bearing carrier gear housing contact surfaces
Water pump base O-ring and carrier seal lips
Page 6C-2 90-8M0082471 JULY 2014

Special Tools

location, and TDC.
9479
Dial indicator holding fixture.

2999
Secures the dial indicator to gear housing when checking backlash.
29496
46139
9514
Retaining Nut Wrench 918M0070085
Install locknut onto forward gear hub
55843
Installs the bearing cup into the forward gear bearing adapter
9445
90-8M0082471 JULY 2014 Page 6C-3

9520
28677
Removes bearings from gears and the driveshaft.
8505
Driver Rod 9137323
25431 Aids in the removal and installation of various bearings and bearing races
Removes pinion bearing from gear housing
49079
Used in pinion gear and pinion bearing installation
29490
Page 6C-4 90-8M0082471 JULY 2014

Bearing Removal and Installation Kit 91 31229A 7

Installs and removes the bearings in all gearcases. All components can be
91 31229A 7 tool assembly includes the following components:
11 24156 Hex Nut
12 34961 Washer
91 15755T Needle Bearing Driver
91 29310 Plate
91 30366T 1 Mandrel
91 31229 Puller Shaft
91 32325T Driver Head
91 32336 Needle Bearing Driver
91 36379 Puller and Head Gear
91 36571T Pilot Washer
91 37292 Roller Bearing
91 37311 Driver Head
2966 91 37323 Driver Head Rod
91 37324T Pilot Washer
91 37350T Pilot Mandrel
91 38628T Puller and Driver Head
91 52393T Pinion Bearing Installation Tool
91 52394 Head Pull Rod
6761
Bearing Cup Driver/Oil Seal Installer Tool 91888414T01
Installs bearing carrier cup and seals.

6229
Mandrel 918M0060057
Install reverse gear bearing in lefthand rotation gearcase
48575
Mandrel 918M0070938
Installs the LH reverse gear bearing adapter
56256
Mandrel 918M0070955
Installs the reverse gear bearing adapter
49522
90-8M0082471 JULY 2014 Page 6C-5

lefthand gear case
49525
49523
49263
47416
measurements
8756
2
3
1
4
8
7 5
6
56235
Page 6C-6 90-8M0082471 JULY 2014

56254
Provides access hole to measure pinion depth
49549
Preload Driver 918M0071639
Used with torque wrench to check rolling torque of the lefthand forward gear
assembly
55844
Backlash Indicator Rod 918M0053505
46158

47536
Used for pressure testing of closed systems (gear housing, fuel lines, cooling).
29497
90-8M0082471 JULY 2014 Page 6C-7


20
19
20
21
22 23
24
25
26
27
18
12 11
28
29
30
13 31
32
14 38 33
15 34
39
16 35
40
17 36
41
9
5
37
7
6
4
6
8
2 10
3
1
55146
Page 6C-8 90-8M0082471 JULY 2014


Torque
2 2 Vent screw 11.3 100
3 4 Seal
4 1 Dowel pin
6 2 Anode
7 1 Screw (M6 x 40) 6.8 60
8 1 Nut (M6)
9 1 Screw (0.43714 x 1.750) 54 40
10 1 Trim tab anode
12 1 Ering
13 1 Retaining ring
14 2 Washer
15 1 Oil seal
17 1 Oring
18 1 Driveshaft
20 2 Oring
21 4 Screw (M6 x 20) 6.8 60
22 1 Face seal
23 1 Filler block
25 1 Key
27 1 Faceplate
28 1 Retaining ring
31 1 Oring
32 1 Retainer 135.5 100
34 1 Tapered roller bearing assembly
35 1 Shim
37 1 Shim set
38 1 Needle bearing
40 1 Washer
90-8M0082471 JULY 2014 Page 6C-9

Torque
41 1 Nut (0.62518) 67.8 50
Page 6C-10 90-8M0082471 JULY 2014


20
19
20
21
22 23
24
25
26
27
18
12 11
28
29
30
13 31
32
14 38 33
15 34
39
16 35
40
17 36
41
9
5
37
7
6
4
6
8
2 10
3
1
55146
90-8M0082471 JULY 2014 Page 6C-11

Gear Housing (Propeller Shaft Command Thrust 2.38:1 LeftHand Rotation)
24
23
1 22
21
18
19
20
19
18
17
16 14
15
13
12
11
2
3
4
5
6
7
8
9
10 36
35
34
31
29
27
28
26
33 32
30
25
55148
Page 6C-12 90-8M0082471 JULY 2014

Gear Housing (Propeller Shaft Command Thrust 2.38:1 Left-Hand Rotation)

Torque
3 1 Retaining ring
4 1 Thrust washer
5 1 Bearing cup
7 1 Thrust bearing
8 1 Thrust washer
9 1 Needle roller bearing assembly
10 1 Reverse gear bearing adapter
11 1 Cam follower
12 1 Shift cam
14 1 Six jaw sliding clutch
15 1 Retaining spring
16 1 Cross pin
19 2 Bearing cup
20 1 Forward gear bearing adapter
21 1 Thrust washer
22 1 Locknut
23 1 Set screw (half dog point) 1.7 15
24 1 Spacer shim
26 1 Oring (3.975 x 0.210)
27 1 Bearing cup
29 1 Bearing carrier
30 1 Thrust spacer
31 2 Oil seal
32 1 Fill screw 11.3 100
33 1 Seal
34 1 Tab washer
35 1 Retainer 285 210
90-8M0082471 JULY 2014 Page 6C-13


There may be more than one way to disassemble and assemble a particular part. It is recommended the entire procedure be
Service procedure order in this section is a normal disassembly/assembly sequence. It is suggested that the sequence be
followed without deviation to assure proper repairs. When performing partial repairs, follow the instructions to the point where
the desired component can be replaced, then proceed to the assembly and installation of that component in the assembly part
of this section. Use the Table of Contents to find the correct page number.
Bearings
be replaced.
Shims
Keep a record of all shim amounts and their location during disassembly to aid in reassembly. Be sure to follow the shimming
instructions during reassembly, as gears must be installed to the correct depth and have the correct amount of backlash to
avoid noisy operation and premature gear failure.
Seals

! WARNING

Page 6C-14 90-8M0082471 JULY 2014

b a- Tab washer
f
d- Rear thrust hub
e- Propeller shaft
f- Front thrust hub
d c e
48808
a a - Rubber cover
55957
a - Screw
48236
90-8M0082471 JULY 2014 Page 6C-15

48245

a - Fill screw
b - Vent screw
a
48252

Page 6C-16 90-8M0082471 JULY 2014

3. Check the propeller shaft for axial end play. End play should be 0.3301.22 mm (0.0130.048 in.).

d c- Dial indicator
3234
Propeller Shaft
Runout 0.152 mm (0.006 in.)
End play 0.3301.22 mm (0.0130.048 in.)


1. Remove the shift shaft rubber washer.
48582
90-8M0082471 JULY 2014 Page 6C-17

a - Vring face seal

c - Screws (M6 x 20) (2 each side)
a
b
c 48265

a a - Impeller
b - Drive key
48268
7. Remove the water pump face plate and both gaskets from the gear housing.
a
b - Face plate
c - Metal gasket
48269
Page 6C-18 90-8M0082471 JULY 2014


1. Inspect the face plate and water pump liner for grooves or rough surfaces.
2. Inspect the stainless steel gasket coated surface for scratches or damage. If the coating is scratched or damaged, replace
the stainless steel gasket.
a - Stainless steel gasket

a
b - Coating
b
46007
4. Inspect the impeller bonding to the impeller hub.
b a
a - Impeller
b - Hub
28496

Removal

b - Retaining ring
48281
90-8M0082471 JULY 2014 Page 6C-19


c - Protective pad
a
c
b
48284

b - Oring
48291
Disassembly

Page 6C-20 90-8M0082471 JULY 2014

a - Retainer nut
c - Lock tabs
a
b
c
48306
4. Remove the gear housing retainer nut and propeller bore sleeve with the bearing carrier retainer nut wrench.

a
55955

48311
6. Verify that the gear housing is in neutral. Remove the shift shaft bushing retaining ring.
90-8M0082471 JULY 2014 Page 6C-21

a - Shift shaft
c - Retaining ring
b
48315

a
48317
Page 6C-22 90-8M0082471 JULY 2014

d
a
b
48555
a- Long jaws
b- Puller bolt
c- Thrust hub
e- Shift shaft



1. Remove the propeller shaft oil seals from the bearing carrier with a drift punch.
a - Drift punch
b - Seals (2)
a c - Bearing carrier
55849
90-8M0082471 JULY 2014 Page 6C-23

2. Place the bearing carrier in a vise, clamping on the reinforcing rib.
3. Remove the bearing cup using a slide hammer puller.
a a- Slide hammer puller

b- Bearing cup (inside of bearing carrier
b
c- Bearing carrier
d- Reinforcing rib
3141

1. Remove the bearing, thrust washers, thrust spacer, and shift cam from the propeller shaft.
b c d e
a
55745
a- Propeller shaft
b- Bearing
c- Thrust washer
d- Thrust spacer
e- Shift cam
3. Inspect the area of the oil seals for grooves. Replace the propeller shaft if grooves are found.
4. Inspect the bearing surfaces of the propeller shaft for pitting, grooves, scoring, uneven wear, or discoloration from
overheating. Replace the shaft and corresponding bearing if any of the previous mentioned conditions are found.
5. Inspect the propeller shaft splines for wear and/or corrosion damage.
Page 6C-24 90-8M0082471 JULY 2014

Position the propeller shaft roller bearing surfaces on balance wheels or Vblocks. Use a dial indicator at the front
edge of the propeller splines. Rotate the propeller shaft. Dial indicator movement more than the specification requires
the propeller shaft to be replaced.
a - Dial indicator location

b - Bearing surface
b b
55756
Propeller Shaft
Runout 0.152 mm (0.006 in.)

1. Remove the retaining spring with an appropriate tool. Do not overstretch the retaining spring.
a a - Awl
b b - Retaining spring
55739
2. Push the cross pin out of the clutch and propeller shaft with an appropriate tool.
a - Cross pin
b - Clutch
b
a
55740
3. Remove the clutch from the propeller shaft.

4. Inspect the clutch for damage. Damage to the clutch indicates one or more of the following:
90-8M0082471 JULY 2014 Page 6C-25

a. Improper shift cable adjustment

b. Improper shift technique shifting too slow
c. Engine RPM too high while shifting
6. Disconnect the clutch actuator rod from the cam follower.
a- Forward gear assembly

b- Clutch
c- Clutch actuator rod
d- Cam follower
c
d
a b 55741
7. Check the condition of the cam follower. If it shows wear, pitting, scoring, or rough surface, replace the cam follower and
shift cam.
8. Remove the forward gear assembly.
a
a - Forward gear assembly
55742
Forward Gear and Bearing Adapter Disassembly

1. Clamp the propeller shaft in a soft jaw vice.
2. Install the clutch onto the propeller shaft.
Page 6C-26 90-8M0082471 JULY 2014

3. Install the cross pin through the clutch and propeller shaft.
a- Soft jaw vice

b- Propeller shaft
d c- Cross pin
d- Clutch
c
b
a
55760
4. Install the forward gear assembly onto the propeller shaft/clutch.

5. Loosen the set screw in the locknut.
6. Using the retaining nut wrench, loosen the locknut.
a- Breaker bar
b- Retaining nut wrench
c- Set screw
b a d- Forward gear
c
55750

7. Remove the locknut from the forward gear assembly.
90-8M0082471 JULY 2014 Page 6C-27

8. Remove the tapered roller bearings, and thrust washer from the forward bearing adapter.
e a- Forward gear (31 teeth)

b- Tapered roller bearing
c- Bearing adapter assembly (includes bearing cups)
d d- Thrust washer
e- Locknut
f- Special set screw
f b
55763
9. Remove the special set screw and inspect the brass point. Replace if necessary.
10. Inspect the clutch dog teeth on the forward gear for signs of wear. Replace the gear and clutch if necessary.
11. Inspect the forward gear clutch dog teeth for damage. Replace if necessary.
12. Inspect the thrust washer for pitting, rust, or signs of discoloration. Replace if any of these conditions are found.
13. Carefully inspect the tapered roller bearings for pitting, rust, or signs of discoloration. Replace the bearing if any of these
Bearing Adapter Assembly

1. Inspect the bearing cups in the bearing adapter. If the bearing cups require replacement, use a drift punch to drive the
bearing cups out of the adapter.
a - Drift punch
b - Bearing cup
c - Bearing adapter
a
b
56266
Page 6C-28 90-8M0082471 JULY 2014

2. Use bearing cup driver 8M0073870 to press the new bearing cups into the bearing adapter with the numbers/letters facing
into the bearing adapter.
a - Bearing cup driver

b - Bearing adapter
a
56267

48340


driveshaft.
90-8M0082471 JULY 2014 Page 6C-29

the 18 rollers.
a - Wood block
b a
48341
covers.
a - Upper bearings
a
56202

16. Install the bearing driver tool into the pinion bearing and insert the driver rod into the gearcase and mandrel.
17. Install the pilot washer over the driver rod and into the gear housing to align the removal tools.
Page 6C-30 90-8M0082471 JULY 2014

a - Bearing driver tool

b - Pilot washer
c - Driver rod
48344
Driver Rod 9137323


! WARNING
b a - Splines
a c a
56198
90-8M0082471 JULY 2014 Page 6C-31

Reverse Gear Removal and Disassembly

1. Remove the reverse gear from the gear housing.
39779
2. Remove the thrust bearing and thrust washer from the bearing adapter. Inspect the thrust bearing and washer for pitting,
rust, or discoloration. Replace the components if any of these conditions are found.
a - Thrust bearing
a b - Thrust washer
c - Bearing adapter
c
39782
3. Use the two jaw puller, a threaded rod, washer, and guide plate to remove the reverse gear bearing adapter.
a a- Threaded rod
c b- Nut
b c- Washer
d d- Guide plate
e- Two jaw puller head
e
39787


1. Clean the reverse gear and bearing with a mild solvent. Dry with compressed air. Do not spin the bearing.
! WARNING
Page 6C-32 90-8M0082471 JULY 2014

3. Inspect the clutch dogs on the reverse gear for damage. Replace the reverse gear if damage is found.
a - Gear teeth
b - Clutch dogs
39789
4. Inspect the needle bearings on the inside of the reverse gear. Inspect the bearing surface on the propeller shaft. If either
the needle bearings, or the bearing surface of the propeller shaft are pitted, grooved, worn unevenly, discolored, or has
embedded particles, replace the propeller shaft and needle bearing in the reverse gear.
NOTE: The needle bearing in the reverse gear should not be removed unless damaged.
6. Use a suitable mandrel to press the bearing out of the gear.
c
a e
b
d
55792
a- Propeller shaft
b- Reverse gear
c- Retaining ring
d- Numbered side of bearing
e- Needle bearing

90-8M0082471 JULY 2014 Page 6C-33

a
49365
holes.

2. Install the pinion bearing onto the mandrel so the letter and number side of the bearing is facing up.
3. Insert the mandrel and bearing into the gear housing pinion bearing bore.
4. Install the puller plate onto the puller rod and insert the puller rod into the gear housing driveshaft bore. Thread the puller
rod into the mandrel.
5. Secure the puller rod and tighten the nut until the mandrel contacts the gear housing.
a- Puller rod
b- Puller plate
a c- Pilot washer
d- Pinion bearing
f e- Mandrel
b f- Hex nut
e
48693

Page 6C-34 90-8M0082471 JULY 2014

Forward Gear Bearing Carrier Assembly

1. Lubricate the outside diameter of the bearing cup with High Performance Gear Lubricant.
2. Press the numbered side of the bearing cup into the bearing carrier until the bearing cup is seated in the bearing carrier.
a - Bearing carrier
b - Driver
c - Bearing cup
b
c
55786

87 Outside diameter of bearing cup 92-858064K01
Lubricant

3. Ensure that the bearing carrier bore is clean and dry.
4. Install the first seal onto the long shoulder side of the oil seal driver mandrel. Verify that the seal lip faces away from the
mandrel shoulder. Press the seal into the bearing carrier until the mandrel contacts the bearing carrier.
a - Oil seal
b - Bearing carrier
c - Mandrel
a
b
55776

5. Apply Loctite 271 Threadlocker to the outside diameter of the second propeller shaft oil seal.
90-8M0082471 JULY 2014 Page 6C-35

6. Install the second seal onto the short shoulder side of the oil seal driver mandrel. Verify that the seal lip faces towards the
mandrel shoulder. Press the seal into the bearing carrier until the mandrel driver contacts the bearing carrier.
a - Oil seal
b - Bearing carrier
c - Mandrel
a
b
55777

7 Loctite 271 Threadlocker Outside diameter of the second propeller shaft oil seal 92-809819

7. Apply 24C with PTFE to the oil seal lips.

95 2-4-C with PTFE Oil seal lips 92-802859A 1
Reverse Gear and Bearing Adapter Assembly

Reverse Gear Assembly
1. Lubricate the outside diameter of the propeller shaft needle bearing with High Performance Gear Lubricant.
2. Place the reverse gear onto a press with the teeth facing down.
3. Install the propeller shaft needle bearing with the numbers facing up towards the mandrel.
4. With the mandrel inserted into the bearing, press on the numbered side of the bearing until the mandrel contacts the gear.
a - Mandrel
b - Bearing (numbers face up)
c - Reverse gear
a
b
c
48576
Page 6C-36 90-8M0082471 JULY 2014


87 Outside diameter of propeller shaft needle bearing 92-858064K01
Lubricant
Mandrel 918M0060057
Bearing Adapter Assembly

1. Lubricate the inside diameter of the bearing adapter and the outside diameter of the bearing with High Performance Gear
Lubricant.
2. Place the bearing with the numbers facing up on a press.
3. Press the bearing into the bearing adapter with a suitable mandrel until the mandrel contacts the bearing adapter.
a - Mandrel
b - Bearing adapter
a c - Bearing
39937

High Performance Gear Inside diameter of the bearing adapter and the outside
87 92-858064K01
Lubricant diameter of the bearing
Mandrel 918M0070938
Reverse Gear Bearing Adapter and Gear Installation

1. Lubricate the outside diameter of the bearing adapter with 24C with PTFE.
2. Position the bearing adapter into the gear housing bore.
a - Bearing adapter
49253

95 2-4-C with PTFE Outside diameter of bearing adapter 92-802859A 1
90-8M0082471 JULY 2014 Page 6C-37

3. Install the reverse gear bearing mandrel into the bearing adapter.
a - Mandrel
b - Bearing adapter
b
49535
Mandrel 918M0070955
4. Install the pilot ring onto the driver tool and install the tool assembly into the gear housing. Verify the pilot ring is seated on
the gearcase ledge.
5. Thread the adapter into the gearcase bearing carrier retainer threads and install the driver screw into the adapter.
6. Secure the adapter and thread the driver screw in until the bearing adapter is seated in the gear housing.
IMPORTANT: Do not overtighten the driver screw. Overtightening the driver screw will damage the bearing inside the
bearing adapter.
c d a- Driver screw
a b b- Adapter (8M0048035)
c- Driver tool
d- Installer pilot (8M0048109)
e- Mandrel (8M0070955)
f- Bearing adapter
g- Shims
e g
f
49534

Mandrel 918M0070955
IMPORTANT: Bearing cup/adapter installation tool 9118605A2 can be used to install the righthand forward gear bearing
race and the lefthand reverse gear bearing adapter if retainer installer tool 918M0048109 and installer pilot
918M0048035 are used.
7. Remove the adapter, pilot ring, and driver tool from the gear housing.
8. Install the thrust washer onto the bearing adapter.
Page 6C-38 90-8M0082471 JULY 2014

9. Lubricate the thrust bearing and thrust washer with 24C with PTFE and install the bearing onto the thrust washer. The
24C with PTFE will help keep the thrust washer and thrust bearing in position during assembly.
a - Thrust bearing
b - Thrust washer
a c - Bearing adapter
b c
39961

95 2-4-C with PTFE Thrust washer and thrust bearing 92-802859A 1
10. Install the reverse gear onto the bearing adapter.
a - Reverse gear
b - Thrust bearing and thrust washer
a
39962
Driveshaft Assembly
driveshaft
driveshaft.
a- Used pinion nut

a b- Driveshaft
c- Bearing
e
48776
90-8M0082471 JULY 2014 Page 6C-39


Lubricant

driveshaft.
a- Pinion nut
b- Driveshaft
c
d e
f
48778

Lubricant

checked.


Page 6C-40 90-8M0082471 JULY 2014

a a- Driveshaft
b- Pinion gear
g c- Washer
d- Pinion nut
f
e- Forward gear
e
b
c
d 56244



b- Bearing retainer
b
c
d
e
f 49267


90-8M0082471 JULY 2014 Page 6C-41


b- Torque wrench
c- Socket
b d- Breaker bar
a
a
d 48797

Pinion nut 67.8 50

Pinion Gear Depth

IMPORTANT: The reverse gear assembly pilots the end of the pinion gauge and must be installed in the gear housing when
specifications.
bearings.
Page 6C-42 90-8M0082471 JULY 2014

d a- Coupler
b- Threaded rod
f- Set screw (2)
f g- Bolt
g h- Spring
m i- Thrust washer
h j- Thrust bearing
b k- Adapter
i l- Plate
j m- Nut
a k
l
13288

a a - Bolt head
b - Nut
7275
screw.
c. Place the adapter tool on the arbor handle with side B toward the forward gear.
d a- Arbor handle
e
2 b- Screw (2)
3
8 4 d- Split collar
7 5
6
a f
b Side B toward the forward gear
b 48984
90-8M0082471 JULY 2014 Page 6C-43


NOTE: Pinion gear locating tool 9112349A05 may be used to determine pinion depth if a pinion gauge adapter tool is
locating disc.
a - Gauging block
a
7279
2.1L Command Thrust 2.38:1 (13/31) 4 4
a b - Access hole
b
7282

Page 6C-44 90-8M0082471 JULY 2014

d a- Feeler gauge
c- Pinion gear
7283
15. Remove the preload tool.
16. Install the spacer shim into the gear housing.

IMPORTANT: The propeller shaft with the forward gear bearing adapter and bearing carrier assembly must be assembled and
installed in the gear housing before the forward gear backlash can be checked.
1. Lubricate the two tapered roller bearings with High Performance Gear Lubricant.
2. Install one tapered roller bearing onto the forward gear.
3. Install the bearing adapter onto the tapered roller bearing with the flange side toward the forward gear.
4. Install the second tapered roller bearing into the bearing adapter.
5. Install the thrust washer onto the forward gear.
6. Thread the lock nut onto the forward gear until handtight.
e a- Forward gear
b- Tapered roller bearing
c- Bearing adapter assembly (with bearing cups)
d d- Thrust washer
e- Locknut
f- Special set screw
f b
55765

87 Forward gear tapered roller bearings 92-858064K01
Lubricant
7. Clamp the propeller shaft in a soft jaw vice.
90-8M0082471 JULY 2014 Page 6C-45

8. Install the clutch onto the propeller shaft.
9. Install the cross pin through the clutch and propeller shaft.
a- Soft jaw vice

b- Propeller shaft
d c- Cross pin
d- Clutch
c
b
a
55760
10. Install the forward gear assembly onto the propeller shaft/clutch.
11. Set the bearing preload using the following procedure:
a. Using the retaining nut wrench, tighten the locknut to the specified torque to preload the bearings.
a- Torque wrench
b- Retaining nut wrench
c- Special set screw
d- Forward gear
b a
c
55767

Forward gear assembly locknut 67.8 50

b. Using the preload driver tool, rotate the bearing carrier four rotations and then check the rolling torque.
Page 6C-46 90-8M0082471 JULY 2014

IMPORTANT: Rotate the bearing carrier at 5060 RPM to obtain an accurate rolling torque reading.
a- Torque wrench
a b- Adapter
b c- Preload driver
d- Bearing carrier
c
d
55841

Forward gear bearing rolling torque 1.12.3 1020
Preload Driver 918M0071639

c. If the rolling torque is not within specification, increase or decrease the torque on the locknut in step a, then check the
rolling torque in step b.
d. Tighten the special set screw to the specified torque.

Special set screw 1.7 15
12. Install the forward gear assembly onto the propeller shaft.
a
a - Forward gear assembly
b - Propeller shaft
b
55768
13. Install the clutch as shown with the hole aligned with the slot in the propeller shaft.
14. Install the actuator rod into the slot in the cam follower.
15. Install the actuator rod/cam follower into the propeller shaft.
90-8M0082471 JULY 2014 Page 6C-47

16. Install the cross pin through the clutch, actuator rod, and propeller shaft.
a
a- Clutch
b- Actuator rod
b c c- Cam follower
d- Cross pin
d
55769
17. Install the retaining spring to retain the cross pin. Do not allow the spring coils to overlap each other.
a a - Cross pin (hidden)

b - Retaining spring
b
55770
19. Install the shift cam into the cam follower pocket as shown.
20. Install the thrust spacer, thrust washers, and bearing onto the propeller shaft.
b c d
a
55771
a- Propeller shaft
b- Bearing
c- Thrust washer
d- Thrust spacer
e- Shift cam

95 2-4-C with PTFE Pocket on cam follower 92-802859A 1
Page 6C-48 90-8M0082471 JULY 2014

21. Apply 24C with PTFE to the propeller shaft seal lips and the cavity between the seals.
a - Bearing carrier
a b - Propeller shaft seals
55845

95 2-4-C with PTFE Propeller shaft seal lips and the cavity between the seals 92-802859A 1
22. Lubricate the bearing carrier Oring with 24C with PTFE. Install the Oring onto the bearing carrier.
23. Install the bearing carrier onto the propeller shaft assembly. Align the tab on the forward gear bearing carrier with the notch
in the bearing carrier.
a
a - Oring
b - Notch in the bearing carrier
c - Tab on the forward gear bearing
carrier
b
c
55847

95 2-4-C with PTFE Bearing carrier O-ring 92-802859A 1
24. Apply 24C with PTFE onto the bearing carrier gear housing contact surfaces.
55848

95 2-4-C with PTFE Bearing carrier gear housing contact surfaces 92-802859A 1
90-8M0082471 JULY 2014 Page 6C-49

Shift Shaft Installation

1. Verify that the clutch is in the neutral position and carefully install the propeller shaft and bearing carrier assembly into the
reverse gear located inside the gear housing.
2. Verify that the spacer shim is in place in the gear housing.

b - Bushing
c - Oring
a
19
b
c
95
48440

a
a- Seal
b c- Oring
d- Ering
c e- Shift shaft
48449
Page 6C-50 90-8M0082471 JULY 2014

a - Shift shaft
c - Retaining ring
b
48315
a- Keyed washer
b a
b- Index tab
c- Index tab
d- Locking tab
c
d
d
56250
90-8M0082471 JULY 2014 Page 6C-51

a- Oring
b- Retainer nut
d- Torque wrench
a b c d
95
48512


NOTE: After the gearcase backlash has been set, bend the locking tab washer tab into the retainer nut. Bend the
remaining tabs of the tab washer toward the front of the gear housing.

1. Install the dial indicator adapter to the gear housing. lnstall the backlash indicator rod and dial indicator as shown.
c
d- Dial indicator
e- Threaded rod
d
e
56195

Backlash Indicator Rod 918M0053505
Page 6C-52 90-8M0082471 JULY 2014

the indicator tool or an inaccurate reading will be obtained.

3. Rotate the shift shaft into the forward gear position.
4. Rotate the shift shaft into the neutral position.
5. While holding the shift shaft in the neutral position, rotate the driveshaft approximately 30, reposition the flag, and then
rotate the shift shaft towards the forward gear position. Ideally, the shift shaft should not go into the forward gear position.
The clutch dogs should butt against the forward gear clutch dogs. Hold the shift shaft firmly in this position.
6. While firmly holding the clutch against the forward gear with the shift shaft, lightly rotate the driveshaft backandforth.

0.3300.457 mm
2.38:1 (13/31)
(0.0130.018 in.)
8. If the backlash is less than the minimum specification, install a thicker spacer shim in front of the bearing adapter. If the
backlash is more than the maximum specification, install a thinner spacer shim in front of the bearing adapter.
9. After all backlash measurements are correct, install the propeller bore sleeve onto the bearing carrier retainer nut. Failure
to install the propeller bore sleeve will result in a loss of boat performance.

a
48534
Water Pump Assembly

assembly.
90-8M0082471 JULY 2014 Page 6C-53


b - Oring
c - Filler block
b
c
48519

95 2-4-C with PTFE Water pump base O-ring and carrier seal lips 92-802859A 1

b - Retaining ring
48281
NOTE: The metal gasket may be reused if the black surface is not scratched or damaged. The face plate may be reused if
there are no other grooves other than the impeller sealing ring groove. The fiber gasket may be reused if there is no
damage to the gray neoprene strip or the fiber gasket itself.
Page 6C-54 90-8M0082471 JULY 2014

5. Install a new metal gasket, face plate, and fiber gasket.
a
b - Face plate
c - Metal gasket
48269
IMPORTANT: If the old impeller is being reused, do not install the impeller in reverse rotation to its original set as
premature impeller failure will occur.
a a - Impeller
b - Drive key
48268
impeller.
9. Secure the water pump cover with four screws. Tighten the screws to specification.
90-8M0082471 JULY 2014 Page 6C-55

10. Install the Vring face seal over the driveshaft. Use the Vring installation tool to seat the Vring face seal against the water
pump cover at the proper height.
a - Vring face seal

c - Screws (two each side)
a
b
c 48265


Water pump cover screw (4) 6.8 60

11. Install the shift shaft rubber washer against the shift shaft seal.
48582

housing should hold 103.4 kPa (15 psi) for 15 minutes.
1. Remove the vent plug and install a pressure test gauge.
48537
Page 6C-56 90-8M0082471 JULY 2014

2. Pressurize the housing to 103.4 kPa (15 psi) and observe the gauge for 15 minutes.
Gearcase Test Pressure


Gear Housing Installation (LeftHand Rotation)

55958
NOTICE

c
55962

Grease
90-8M0082471 JULY 2014 Page 6C-57

48245
48236
b. Rotate the flywheel clockwise: the propeller shaft should rotate counterclockwise.
f. Rotate the flywheel clockwise and the propeller shaft should rotate clockwise.
16. Install the anode and secure with the anode screw.
Page 6C-58 90-8M0082471 JULY 2014

a a - Rubber cover
55957

Locknuts (M12 x 1.75) (4) 60 44
Screw (M12 x 35) 75 55
Anode screw (0.43714 x 1.75) 54 40

housing should hold 103.4 kPa (15 psi) of pressure for 15 minutes without leakage. Failure to hold the specified pressure
indicates worn or damaged sealing surfaces or improperly assembled gear housing. The cause of leakage must be corrected
before returning the gear housing assembly into service.
Gear Housing Pressure

Without gear lubricant for 15 minutes without leakage 103.4 kPa (15 psi)
a - Fill screw
b - Vent screw
a
48252
90-8M0082471 JULY 2014 Page 6C-59


Lubricant

Page 6C-60 90-8M0082471 JULY 2014

Throttle/Shift Linkage

Section 7A - Throttle/Shift Linkage
Table of Contents
Integrated Air Fuel Module and Fuel Rail Components..... 7A-4 Shift Bracket Removal..................................................... 7A-11
Shift Linkage Components.................................................7A-6 Shift Bracket Disassembly and Assembly........................7A-13
Throttle Link....................................................................... 7A-8 Shift Bracket Disassembly........................................ 7A-13
Throttle Link Removal ................................................7A-8 Shift Bracket Assembly.............................................7A-13
Throttle Link Installation..............................................7A-9 Shift Bracket Installation.................................................. 7A-15
7
A
90-8M0082471 JULY 2014 Page 7A-1


Throttle link actuator shoulder screw threads
Throttle lever shoulder screw threads
Shoulder of the throttle link actuator shoulder screw and washers
Shoulder of the throttle lever shoulder screw and washers
95 2-4-C with PTFE Shift link pin 92-802859A 1
Cantilever actuator
Bronze bushing
Page 7A-2 90-8M0082471 JULY 2014

Notes:
90-8M0082471 JULY 2014 Page 7A-3


1
2
11 5
6
9
12
10
13
25
26
15 23
16
14
17 8
23
20
21
24
19 22
18
21 20 55125
17
Page 7A-4 90-8M0082471 JULY 2014


Torque
1 1 Screw (M4 x 10) 1.7 15
3 1 MAP sensor
4 4 Screw (M6 x 20) 8 70.8
7 2 Screw (M4 x 16) 1.7 15
9 1 Gasket
10 4 Gasket
14 2 Screw (M6 x 20) 8 70.8
16 1 Swivel bushing
17 2 Shoulder bolt
18 1 Push nut
19 1 Retainer
20 2 Wave washer
21 2 Washer
23 2 Washer
26 2 Screw (M4 x 16) 1.7 15
90-8M0082471 JULY 2014 Page 7A-5

Shift Linkage Components

9
7
6 8
5
4
1
2
12
11 13
10
14
16
17
15
55123
Page 7A-6 90-8M0082471 JULY 2014

Shift Linkage Components

Torque
1 1 Bracket assembly
2 1 Latch
4 1 Washer
5 1 Roller
6 1 Retaining ring
7 1 Retainer assembly
8 1 Position sensor
9 1 Screw (M4 x 13) with flange, stainless steel 8 70.8
10 1 Shift link
11 1 Sensor lever
12 1 Nut (M6), stainless steel 6 53.1
13 1 Washer (0.265 in. x 0.625 in. x 0.0625 in.), stainless steel
14 1 Flanged bushing
15 1 Shift shaft assembly
16 1 Bushing (bronze)
17 1 Shift detent assembly
90-8M0082471 JULY 2014 Page 7A-7

Throttle Link
Throttle Link Removal
1. Remove the screw securing the throttle lever to the intake manifold.
e
b
a
f
d
c
56257
a- Shoulder screw
b- Wave washer
c- Washer
d- Throttle lever
e- Return spring
f- Washer
2. Disconnect the throttle link from the throttle body lever.
56258
3. Remove the screw securing the throttle link actuator to the intake manifold.
Page 7A-8 90-8M0082471 JULY 2014

4. Remove the throttle link rod actuator assembly from behind the intake manifold.
a- Shoulder screw
b- Wave washer
c
b c- Washer
a d- Throttle link actuator
e- Washer
d e
56259
Throttle Link Installation

1. Measure the link rod length. Adjust it if necessary.
a
48704
a - 336 mm (13.23 in.)
2. Install the throttle link rod onto the throttle link actuator.
3. Install the wave washer onto the throttle link actuator shoulder screw.
4. Install the washer onto the throttle link actuator shoulder screw.
screw threads.
6. Insert the shoulder screw with the washers through the throttle link actuator.
7. Install the washer onto the shoulder screw threaded end.
a- Shoulder screw
b- Wave washer
c- Washer
f d- Throttle link actuator
e- Throttle link rod
f- Washer
d
e
c
b
56260
a
90-8M0082471 JULY 2014 Page 7A-9


Shoulder of the throttle link actuator shoulder screw and
95 2-4-C with PTFE 92-802859A 1
washers

66 Loctite 242 Threadlocker Throttle link actuator shoulder screw threads 92-809821
9. Guide the throttle link rod behind the intake manifold and secure the throttle link actuator to the intake manifold. Tighten the
shoulder screw to the specified torque.
a - Throttle link rod

a b - Shoulder screw
56261

10. Connect the throttle link to the throttle body lever.
56258
11. Install the return spring into the throttle lever.
a - Long end
b - Short end
a b
48210
12. Install the wave washer onto the throttle lever shoulder screw.
13. Install the washer onto the throttle lever shoulder screw.
Page 7A-10 90-8M0082471 JULY 2014

screw threads.
15. Insert the shoulder screw with the washers through the throttle lever.
e a- Shoulder screw
b- Wave washer
c- Washer
d- Throttle lever
e- Washer
c d
b
56262
a

95 2-4-C with PTFE Shoulder of the throttle lever shoulder screw and washers 92-802859A 1

66 Loctite 242 Threadlocker Throttle lever shoulder screw threads 92-809821
17. Verify the throttle actuator roller is engaged with the throttle lever.
18. Align the long end of the spring with the boss on the cylinder block.
19. Secure the throttle lever to the intake manifold block with the shoulder screw. Tighten the shoulder screw to the specified
torque.
a - Throttle actuator roller

b b - Long end of the spring
c - Shoulder screw
a
c
56263

Shift Bracket Removal

1. Remove the lower starboard cowl. Refer to Section 5A Lower Cowl Removal.
2. Cut the cable tie securing the fuel hose to the shift bracket. Remove the fuel filter and hose from the bracket.
3. Cut the two cable ties securing the engine harness to the shift bracket.
90-8M0082471 JULY 2014 Page 7A-11

4. Disconnect the engine harness connector from the shift position sensor.
5. Move the speedometer hose out of the way.
c a - Fuel filter
a b b - Bracket
c - Cable tie securing the fuel
hose
e - Cable ties securing the engine
harness
f
e d
e
56287
6. Remove the locknut and washer securing the shift link to the shift shaft.
7. Lift the shift link off of the upper shift shaft and remove the bronze bushing.
a- Shift link
c b- Washer
c- Locknut
a b d- Bronze bushing
e- Upper shift shaft
56288
8. Remove the three screws securing the shift bracket to the powerhead.
56289
Page 7A-12 90-8M0082471 JULY 2014

Shift Bracket Disassembly and Assembly

Shift Bracket Disassembly
1. Remove the screw securing the shift position sensor to the shift bracket. Lift the shift position sensor off the antirotation pin.
a - Screw securing the shift position sensor

b - Antirotation pin
b 49516
2. Remove the Ering securing the roller onto the shift link pin.
3. Remove the roller. The shift link and the cantilever actuator can be removed from the shift bracket.
a - Roller
b - Ering
c - Cantilever actuator
c
b
49518
Shift Bracket Assembly

1. Install the plastic washer with the raised side up onto the shift link pin.
a
49519
a - Plastic washer with the raised side up
2. Apply 24C with PTFE to the shift link pin and install the shift link onto the shift bracket.
3. Install the roller with the beveled edge up onto the shift link pin.
90-8M0082471 JULY 2014 Page 7A-13

4. Secure the roller to the shift link pin with the Ering.
a - Roller with the beveled edge up

b - Ering
a
b
49520

95 2-4-C with PTFE Shift link pin 92-802859A 1
5. Apply 24C with PTFE to the area where the cantilever actuator will be installed.
6. Install the cantilever actuator onto the shift bracket and shift lever.
a - Apply 24C with PTFE
49521

95 2-4-C with PTFE Cantilever actuator 92-802859A 1
7. Secure the cantilever actuator and install the shift position sensor onto the cantilever actuator and shift bracket antirotation
pin.
Page 7A-14 90-8M0082471 JULY 2014

8. Secure the shift position sensor with a M4 x 13 screw. Tighten the screw to the specified torque.
a - Screw securing the shift position sensor

b - Antirotation pin
b 49516

Screw (M4 x 13) 8 70.8
Shift Bracket Installation

1. Apply 24C with PTFE to the bronze bushing and install it onto the upper shift shaft.
a a - Bronze bushing
49524

95 2-4-C with PTFE Bronze bushing 92-802859A 1
2. Install the shift bracket and secure it with three M6 x 25 screws. Tighten the screws to the specified torque.
56289
90-8M0082471 JULY 2014 Page 7A-15


Screws (M6 x 25) (3) 10 88.5
3. Install the shift link onto the upper shift shaft and secure it with a washer and locknut. Tighten the locknut to the specified
torque.
a- Shift link
c b- Washer
c- Locknut
a b d- Bronze bushing
e- Upper shift shaft
56288

Locknut 6 53.1
4. Connect the engine harness connector to the shift position sensor.
5. Secure the engine harness to the shift bracket with two cable ties.
6. Move the speedometer hose so it will not interfere with the shift bracket.
7. Install the fuel filter into the bracket. Secure the fuel hose with a cable tie.
c a - Fuel filter
a b b - Bracket
c - Cable tie securing the fuel
hose
e - Cable ties securing the engine
harness
f
e d
e
56287
8. Install the lower starboard cowl. Refer to Section 5A Lower Cowl Installation.
Page 7A-16 90-8M0082471 JULY 2014

Big Tiller

Section 7B - Big Tiller
Table of Contents
Mounting the Tiller Handle 75/80/90/100/115 (2.1 L) Front Cowl Grommet 75/80/90/100/115 (2.1 L)
FourStroke without Power Steering................................7B-2 FourStroke......................................................................7B-7
Copilot Installation...................................................... 7B-4 Removal and Installation............................................ 7B-7
Mounting the Tiller Handle Models with Power Steering
....................................................................................... 7B-5
7
B
90-8M0082471 JULY 2014 Page 7B-1

Big Tiller

Threads of the high-strength screw and locknut
81 Anti-Seize Compound Threads on mounting bolt and locknut 92-898101385
Threads on the bolt and locknut
95 2-4-C with PTFE Copilot rod and link rod ends 92-802859A 1
Mounting the Tiller Handle 75/80/90/100/115 (2.1 L) FourStroke without

Power Steering
1. Apply a thin coating of AntiSeize Compound onto the threads of the highstrength screw and locknut.

81 Anti-Seize Compound Threads of the high-strength screw and locknut 92-898101385
2. While holding the Big Tiller in place on the outboard steering arm, install the highstrength screw through the hole on the
Big Tiller mounting bracket, and tighten it onto the outboard steering arm by hand. Then, thread the locknut onto the
highstrength screw from beneath the outboard steering arm. Do not tighten the fasteners at this time.
a a - Highstrength screw
b - Locknut
b a
b
b
55582
3. Place the locking tab washers onto the two 5/16 x 2.25 in. screws.
4. Place the hardened steel flat washers onto the two 5/16 x 2.25 in. screws.
a b a - Locking tab washers

b - Hardened steel flat washers
52348
Page 7B-2 90-8M0082471 JULY 2014

Big Tiller
5. Install the two 5/16 x 2.25 in. screws and tighten them by hand.
55584
6. Tighten all the fasteners in the correct torque sequence. Refer to the torque sequence table following.
Torque Sequence Table
c b 55585
Torque Sequence Nm lbin. lbft

Step 1 Tighten screws "a" and "b" by hand Fingertight
Step 2 Tighten screws "b" to the first torque setting 7 62
Step 3 Tighten screw "a" to the specified torque 61 45
Step 4 Tighten screws "b" to the final specified torque 30 22
Step 5 Tighten locknut "c" to the specified torque 20 177
7. Bend the locking tab washers against the heads of the two screws.
a - Locking tabs
55586
90-8M0082471 JULY 2014 Page 7B-3

Big Tiller
Copilot Installation
! WARNING
Incorrect copilot assembly installation can cause serious injury or death due to loss of boat control. Install and adjust the
copilot to maintain sufficient steering friction, preventing the outboard from steering into a full turn when the tiller handle is
released.
IMPORTANT: The friction knob must be positioned downward to avoid interference with the link rod.
1. Thread the friction knob assembly onto the tilt tube until it is tight.
2. If the friction knob is not facing downward as shown, rotate the tilt tube to reposition the friction knob as follows:
a. Loosen the tilt tube by loosening the hex nut on the starboard side of the tilt tube.
b. Rotate the tilt tube by turning the hex nut on the port side. Turn the tilt tube until the friction knob is facing downward,
as shown.
c. Tighten the tilt tube by tightening the hex nut on the starboard side.
34543
b a c
a - Friction knob assembly

b - Friction knob facing downward
c - Hex nut
3. Lubricate the copilot rod with 24C with PTFE. Slide the copilot rod into the friction knob assembly.
4. Lubricate both ends of the link rod with 24C with PTFE. Install the link rod onto the copilot rod and to the adapter, as
shown. Tighten the locknuts until tight, and then back off 1/4 turn.
d a- Link rod
c b- Bushing
c- Flat washer
d- Locknut
b e- Copilot rod
a
95
95
b
c
d 95 34565
e
Page 7B-4 90-8M0082471 JULY 2014

Big Tiller

95 2-4-C with PTFE Copilot rod and link rod ends 92-802859A 1
5. Ensure that the link rod does not interfere with the friction knob. Tilt the outboard up and steer the outboard side to side to
check for link rod interference. If necessary, reposition the friction knob farther away from the link rod.
6. Tighten the copilot friction knob to provide the desired steering friction.
Mounting the Tiller Handle Models with Power Steering

1. Place the adapter onto the steering arm and align the front mounting holes with the holes in the steering arm by threading
the two 5/16 x 5 in. screws a few turns into the steering arm.
a - Adapter
b - Screw (5/16 x 5 in.)temporarily installed
b 56283
2. Apply a thin coating of AntiSeize Compound on the threads of the bolt and locknut.
3. Position the steering link arm with the "T" mark facing up. Fasten the steering link arm and bushing to the adapter, as
shown. Do not tighten the bolt and locknut at this time.
a
81
d
T
c
81
a
e b
d
56284
a- Bolt and washer

b- Stainless steel bushing
c- Nylon bushing
d- Steering link armletter "T" facing up
e- Locknut
90-8M0082471 JULY 2014 Page 7B-5

Big Tiller

81 Anti-Seize Compound Threads on mounting bolt and locknut 92-898101385
4. Remove the two 5/16 x 5 in. screws from the adapter.
5. Place the locking tab washers on the two 5/16 x 5 in. screws.
6. Place the hardened steel flat washers on the two 5/16 x 5 in. screws.
a b a - Locking tab washers

b - Hardened steel flat washers
32514
7. Apply a thin coating of AntiSeize Compound on the threads of the bolt and locknut.
8. Install the tiller handle onto the adapter with the bolt and washer, locknut, and the two 5/16 x 5 in. screws, as shown.
81 a a- Bolt and washer

b- Locknut
c- Screw (5/16 x 5 in.)
d- Locking tab washers
e- Hardened steel flat washers
e d 34475

81 Anti-Seize Compound Threads on the bolt and locknut 92-898101385
9. Tighten all the fasteners to the specified torque and in the sequence listed in the following table.
Page 7B-6 90-8M0082471 JULY 2014

Big Tiller
Torque Sequence Table
a
b
c
55846
e d

Step 1 Tighten bolts "a" and "b" fingertight Fingertight
Step 2 Tighten screws "c" to the first torque setting 7 62
Step 3 Tighten bolts "a" and "b" to the specified torque 61 45
Step 4 Tighten screws "c" to the final specified torque 30 22
Step 5 Tighten locknuts "d" and "e" to the specified torque 20 177
10. Bend the locking tab washers against the heads of the two screws.
a - Locking tabs
34481
Front Cowl Grommet 75/80/90/100/115 (2.1 L) FourStroke

Removal and Installation
IMPORTANT: Sufficient slack must exist in the wiring harnesses, battery cables, and hoses, that are routed between the rubber
grommet and engine attachment points, to relieve stress and prevent hoses from being kinked or pinched.
90-8M0082471 JULY 2014 Page 7B-7

Big Tiller
1. Remove the three screws securing the grommet cover to the cowl. Remove the grommet cover.
a - Screws securing the grommet cover to the cowl (3)
55587
2. Route the power steering pump harness (if applicable), remote wiring harness, and cables through the correct openings in
the front grommet, as shown.
NOTE: The power steering pump harness location will need to be opened to install the power steering pump harness
through the front grommet.
a a- Battery cable opening

g b- Tiller handle 14pin harness opening
b
c- Power steering pump harness location
d- Shift cable opening
f e- Speedometer tube opening
f- Fuel hose opening
g- Throttle cable opening
c
e
d 55588
3. Reinstall the grommet cover with the three mounting screws. Tighten the screws to the specified torque.
a a - M6 x 50 screw location
b - M6 x 30 screw location (hidden)
c - M6 x 30 screw location
b
c
55589

Grommet cover mounting screws (M6 x 50) (1) and (M6 x 30) (2) 8 70.8
Page 7B-8 90-8M0082471 JULY 2014

Color Diagrams
Color Diagrams
Section 8A - Color Diagrams
Table of Contents
75/90/115 2.1L FourStroke EFI and EU 80/100/115 2.1L Fuel Flow Diagram.............................................................8A-6
FourStroke EFI Engine Harness.................................... 8A-4 Oil Flow Diagram............................................................... 8A-7
Water Flow Diagram.......................................................... 8A-5
8
A
90-8M0082471 JULY 2014 Page 8A-1

Color Diagrams
Notes:
Page 8A-2 90-8M0082471 JULY 2014

Color Diagrams
Notes:
90-8M0082471 JULY 2014 Page 8A-3

Color Diagrams
75/90/115 2.1L FourStroke EFI and EU 80/100/115 2.1L FourStroke EFI

Engine Harness
1- Engine control module (ECM) 23 - Manifold absolute pressure (MAP) sensor
2- Manifold air temperature (MAT) sensor 24 - Fuse block
3- Idle air control (IAC) valve AB: 20amp mini fuse fuel delivery
4- Throttle position sensor (TPS) CD: 20amp mini fuse ignition system
5- Shift position sensor
EF: 15amp mini fuse 14pin remote control
6- Fuel injector #1 harness/cowl trim switch
7- Fuel injector #2
GH: 2amp mini fuse vessel accessory
8- Fuel injector #3 harness
9- Fuel injector #4 25 - Crankshaft position sensor (CPS)
10 - Start relay 26 - Main power relay
11 - Block pressure sensor 27 - CAN terminator
12 - Ignition coil #1 and #4 28 - Block coolant temperature sensor
13 - To starter motor 29 - Analog trim position sensor
14 - Ignition coil #2 and #3 30 - Remote control
15 - Trim up relay 31 - Oil pressure sensor
16 - To trim pump motor up 32 - Fuel supply module (FSM) pump
17 - To trim pump motor down 33 - Accessory power
18 - Trim to power stud 34 - Vessel accessory harness
19 - Trim to engine ground 35 - Pitot sensor
20 - Trim down relay 36 - Digital trim
21 - Cowl trim switch 37 - Digital trim
22 - SmartCraft boat sensor harness connector (optional 38 - Digital trim
accessory)
The following graphic shows the pin number location on the connector.
17 1
33 18
50 34
66 51
70 69 68 67 48714
Page 8A-4 90-8M0082471 JULY 2014

30 30
3 4 5 6 7 8 9 11
75/90/115 2.1 L 4-Stroke EFI and 87A
85
86 85 12 14 86
EU 80/100/115 2.1 L 4-Stroke EFI
10 13
Engine Harness 87 15 87 16 17
S/N 2B095049 and Above
2 1
C BA C BA BA C A B A B 86 30 8587A 87
86 30 85 87
2 1 2 1 2 1 2 1
RED/BLU
WHT/LT BLU
GRN
BLU
BLU
RED
BLK/WHT
LT BLU/WHT
BLK
BLK/ORN
PPL/YEL
BLK/ORN
WHT/GRN
LT BLU/WHT
RED/BLU
RED/BLU
RED/BLU
RED/BLU
BLK/BLU
RED/BLU
GRN
RED
YEL/RED
YEL/RED
GRN/RED
BLK/ORN
PPL/YEL
RED/YEL
RED/YEL
BLU/YEL
PPL/YEL
BRN/PNK
RED/PNK
ORN/PNK
YEL/PNK
B BLK/ORN
2 A TAN
RED 18
RED
BLK
1
BLK 19
S119 BLK 86
2 BLK/WHT RED
3 WHT/LT BLU 87
4 GRY BLK 86
87A
5 BLK 87A
6
30
87 30
7 TAN/PPL S120 GRN
8 YEL/PPL RED/BLU RED/BLU
RED
9 RED/BLU RED RED/BLU

RED
RED/BLU 85 85
10
11
BLK/GRN RED/BLU RED RED
S106
GRN/WHT
20
12 LT BLU S104
13 WHT RED/BLU
14 RED RED/BLU
15 GRY/BLU
16
17 RED/BLU S105
18 YEL/RED RED/BLU RED
RED/BLU
19 RED/BLU RED/BLU
20 TAN
21 TAN/BLK
22 YEL
23 WHT
24 BLU
25
26 S117 PPL/YEL
27 PPL/YEL
28 BLU/WHT PPL/YEL
29 WHT/BLU S117 PPL/YEL
30 PPL/YEL
31 PPL/YEL
32 GRN
33 GRN/RED
34 PPL/YEL S115
35 WHT/GRN BLK/ORN
1 36
37
WHT/ORN BLK/ORN
BLK/ORN
38 TAN/ORN BLK/ORN
39
40 PNK/BLK BLK/ORN BLK/ORN
41 BLK/YEL BLK/ORN BLK/ORN
42 BLK/ORN BLK/ORN BLK/ORN
43 BLK/BLU S116
44 YEL/WHT
45
46
47 S121
48 YEL/PNK
49 BRN/PNK
50 RED/PNK LT BLU/WHT 3 L
51 PPL/BLK
52
53
PPL
LT BLU/WHT
GRN/WHT 2
RED/PPL 1
21
54 BLU/YEL
55
56
57 RED/BLU
58 RED/BLU
59
60
61
62
63 TAN/LT BLU
64
65 ORN/PNK
66
67 RED/PPL
68 BLK
69 RED/BLK S108 RED/PPL
70 BLK RED/PPL
BLK RED/PPL RED
RED 18
19 BLK
BLK
S110
S107
S103
S109
38
WHT
WHT
PPL
PPL
PPL
YEL/WHT
PPL/BLK
37
S101
BLK/ORN
RED/BLK
RED/BLU
PPL/YEL
S113
S110
LT BLU
S102
S112
RED/WHT
RED/WHT
RED/ORN
TAN/ORN
BLK/ORN
BLK/GRN
GRY/BLU
BRN/WHT
PNK/BLK
RED/BLU
RED/WHT
RED/YEL
RED/PPL
TAN/PPL
PPL/YEL
PPL/BLK
BLK/GRN
BLK/ORN
RED/ORN
RED/PPL
WHT/BLU
BLU/WHT
RED/PPL
TAN/BLK
WHT/ORN
YEL/PPL
BLK/GRN
PPL/BLK
RED
RED
WHT
YEL
RED
BLU
BLK
PPL
BLK
BLK
PPL
BLK
WHT
RED
BLK
C A B
LT BLU/WHT
B AF J K
TAN/LT BLU
C A B DC B A B A 85 30 86 87
GRN/WHT
BRN/WHT
A D E FG H C B A B C D C B A FE
RED/PPL
YEL/RED
BLK/YEL
B A 2 1
WHT
GRY
BLU
BLK
PPL
36 A B C D E F G H J K L MN P
29 19
33
87
P E 26 24 56233
30 M
C
N D
A
F
27
31 L B G
28 22
34 32
K
J
H
85 86 25 23
Page 8A-4.1 35
90-8M0082471 30
Color Diagrams
Water Flow Diagram
1- Water intake
9 10
2- Water pump
8 3- Exhaust tube
4- Water strainer
6 5- Exhaust manifold
6- Cylinder head
7- Engine block
9- Water pump indicator
5 fitting with strainer
7
10 - Cooling water bypass
11 11 - Head gasket bypass
12 - Thermostat discharge
20 hose
discharge
15 - Sprayer (located in the
driveshaft housing)
17 18 16 - Through the propeller
discharge
19 4 17 - Water to block (engine
running)
18 - Block drain (engine not
12 running)
14
19 - FSM cooling water
supply hose
20 - Flush hose fitting
13
15 2
16
56274
90-8M0082471 JULY 2014 Page 8A-5

Color Diagrams
Fuel Flow Diagram
j
g
f i h f
d
e l
k
b
56251
a- Fuel inlet from vessel h- Siphon tube
b- Lowpressure fuel filter (20 microns) i- Highpressure fuel pump
c- Fuel supply module j- Highpressure fuel
d- Fuel lift pump k- Highpressure fuel hose
e- Recirculation check valve l- Inline fuel filter (located inside the fuel rail)
f- Fuel cooler m- Fuel rail and injectors
g- Fuel pressure regulator
Page 8A-6 90-8M0082471 JULY 2014

Color Diagrams
Oil Flow Diagram
e
c
i
g
b
a
56276
a- Oil sump
b- Oil pump
c- Cylinder block
d- Cylinder head
e- Ball stud adjusters
f- Camshaft
g- Camshaft chain tensioner
h- Oil filter
i- Crankshaft
j- Connecting rods
90-8M0082471 JULY 2014 Page 8A-7

Color Diagrams
Notes:
Page 8A-8 90-8M0082471 JULY 2014

M 75 90 115 - FourStroke - 2.1L

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What are the main components of the engine cooling system?

What are the main components of the engine cooling system?

What are the main components of the fuel system?

What are the main components of the fuel system?

80/100/115 FourStroke 2.

75/90/115 FourStroke 2.1L

90-8M0082471 JULY 2014

Mercury Marine. All rights reserved. Printed in U.S.A.

IMPORTANT: Identifies information essential to the successful completion of the task.

Copyright and Trademark Information

90-8M0082471 JULY 2014 Page 1A-1

Page 1A-2 90-8M0082471 JULY 2014

Fuel System Specifications

90-8M0082471 JULY 2014 Page 1A-3

Charging and Starting Specifications

Page 1A-4 90-8M0082471 JULY 2014

Cylinder Block/Crankcase Specifications

Crankshaft main bearing journal A 47.99348.001 mm (1.88951.8898 in.)

90-8M0082471 JULY 2014 Page 1A-5

Cylinder Head Specifications

Camshaft lobe height (115 HP Intake 47.2046 mm (1.8584 in.)

Valve seat angles (referenced Intake 30, 44 0.25, 60

Page 1A-6 90-8M0082471 JULY 2014

Cylinder Head Specifications

Lubrication System Specifications

90-8M0082471 JULY 2014 Page 1A-7

Power Trim Specifications

Standard Gear Housing Specifications

Command Thrust RightHand Gear Housing Specifications

Page 1A-8 90-8M0082471 JULY 2014

Command Thrust LeftHand Gear Housing Specifications

No. of Approx. Gross Approx. Boat Propeller Part

90-8M0082471 JULY 2014 Page 1A-9

No. of Approx. Gross Approx. Boat Propeller Part

No. of Approx. Gross Approx. Boat Propeller Part

Page 1A-10 90-8M0082471 JULY 2014

No. of Approx. Gross Approx. Boat Propeller Part

90-8M0082471 JULY 2014 Page 1A-11

No. of Approx. Gross Approx. Boat Propeller Part

No. of Approx. Gross Approx. Boat Propeller Part

Page 1A-12 90-8M0082471 JULY 2014

No. of Approx. Gross Approx. Boat Propeller Part

No. of Approx. Gross Approx. Boat Propeller Part

90-8M0082471 JULY 2014 Page 1A-13

No. of Approx. Gross Approx. Boat Propeller Part

Page 1A-14 90-8M0082471 JULY 2014

No. of Approx. Gross Approx. Boat Propeller Part

No. of Approx. Gross Approx. Boat Propeller Part

90-8M0082471 JULY 2014 Page 1A-15

No. of Approx. Gross Approx. Boat Propeller Part

Page 1A-16 90-8M0082471 JULY 2014

90-8M0082471 JULY 2014 Page 1B-1

Lubricant, Sealant, Adhesives

Page 1B-2 90-8M0082471 JULY 2014

Tube Ref No. Description Where Used Part No.

Selecting Replacement Parts For Your Outboard

EPA Emissions Regulations

Emission Certification Label

Inspection and Maintenance Schedule