Service Bulletin

Bulletin No. 2018-10

OEM No. 2018-07

Circulate to: Sales Manager Accounting Service Manager Technician Parts Manager

Start Relay Wire Abrasion—V‑8 200–300 and V‑6 175–225

Models Affected
Models Covered Serial Number Or Year
V‑8 200–300 and V‑6 175–225 FourStroke 2B575233 and below
V‑8 250R, V‑8 300R/300R HD Racing Models 1E080536 and below

Scope
Worldwide

Situation
Mercury Marine has identified a potential issue with the start relay wiring chafing on the upper exhaust tube boot clamp. This
abrasion could cause damage to the wires and may cause unintended starter motor actuation. This service bulletin will guide
the dealer through repositioning of the upper exhaust tube boot clamp and installing corrugated conduit around the start relay
wiring to prevent damage.

Corrugated Conduit Installation

! 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 engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.

! 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.

1. Starting with the negative lead, disconnect both battery cables.

2. Remove the top cowl from the engine.
3. On V‑6 models only, remove the lower cowls from the engine. Refer to the appropriate service manual for complete
removal instructions.
NOTE: For this procedure, it is not necessary to remove the rigging components from the engine when removing the lower
starboard cowl. Skip over the rigging removal instructions and start with removing the starboard lower cowl hardware. After
removing the hardware, support the starboard cowl so it does not fall. The port side cowl can be removed completely.
NOTE: It is not necessary to remove the lower cowls to perform this procedure on V‑8 models. The lower cowls have been
removed in the following photos for visual clarity only.
4. Remove the electrical panel cover.

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

2018-10 OCTOBER 2018 © 2018 Mercury Marine Page 1 / 6

Start Relay Wire Abrasion—V‑8 200–300 and V‑6 175–225

• On V‑8 models, pull the top portion of the electrical panel aft until the pins are clear of the grommets, and then lift up.

V-8 models
a - Pull aft
a b - Lift up

63580
• On V6 models, pull the panel aft.
5. Take note of the location and orientation of the upper exhaust tube boot clamp. Apply anti‑seize compound to the threads
of the upper clamp, then loosen the clamp with a 7/16 in. socket.

Tube Ref No. Description Where Used Part No.

81 Anti-Seize Compound Exhaust tube boot clamp threads 92-898101389

V-8 model shown (4 clamps), V-6 models similar (2 clamps)

a - Upper exhaust tube boot clamp
81

68026

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

Page 2 / 6 © 2018 Mercury Marine OCTOBER 2018 2018-10

 Start Relay Wire Abrasion—V‑8 200–300 and V‑6 175–225

6. Rotate the upper exhaust tube boot clamp inward to allow space for removal of the start relay.

a - Exhaust tube boot clamp

b - Start relay

b
a

68027
7. Remove the start relay from the socket at the base of the electrical panel. Push in on the tab on the back of the relay to
release it from the socket.

a - Start relay
b - Electrical plate

68029

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

2018-10 OCTOBER 2018 © 2018 Mercury Marine Page 3 / 6

Start Relay Wire Abrasion—V‑8 200–300 and V‑6 175–225

8. Pull the start relay harness away from the engine as far as slack will allow. Remove the two cable ties securing the wiring
bundle, if necessary. Inspect the start relay harness for damage from chafing. If damage is observed, repair or replace the
start relay harness before proceeding.

a - Start relay harness

b - Cable ties (2)

b
a

68030
9. Protect the start relay wiring as follows:
a. Wrap the start relay wiring with electrical tape, making sure to cover all the way up to the base of the relay, as shown.
Do not compress or strain the wires at the base of the relay.
b. Install the 31.8 mm (1.25 in.) piece of 0.5 in. inside diameter corrugated conduit (from kit part number 8M0153113)
over the taped starter relay wiring, as shown.
c. Secure the conduit to the relay wiring by wrapping electrical tape around the relay wiring, just below the conduit, and
continue wrapping the tape over the top of the installed corrugate. Secure the conduit with a cable tie as shown.

d
b

c
a

68032

a- Electrical tape
b- Conduit from kit part number 8M0153113 on start relay harness
c- Conduit wrapped with electrical tape
d- Cable tie

10. Install the start relay back into the socket at the base of the electrical panel.
11. Position the upper exhaust tube boot clamp so the spring end is as close to the water pickup tube as possible. Apply
anti‑seize compound to the threads of the clamp, and tighten the nut with a 7/16 in. socket until the spring coils bind.

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

Page 4 / 6 © 2018 Mercury Marine OCTOBER 2018 2018-10

 Start Relay Wire Abrasion—V‑8 200–300 and V‑6 175–225

Tube Ref No. Description Where Used Part No.

81 Anti-Seize Compound Exhaust tube boot clamp threads 92-898101389

a
81
c

d
b

68033

a- Loosened upper exhaust tube boot clamp

b- Water pickup tube
c- 7/16 in. socket
d- Tightened upper exhaust tube boot clamp

12. Secure the wiring bundle with cable ties, if previously removed.

a - Cable ties (2)

68034
13. Install the electrical panel cover.
14. On V‑6 models, install the lower cowls. Refer to the appropriate service manual for complete installation instructions.
15. Install the top cowl.

! 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.
16. Starting with the positive lead, connect both battery cables.

Owner Notification
A letter will be sent to every registered owner of a potentially affected outboard. The letter will advise the owner to take their
outboard to any Mercury Marine authorized dealer for inspection or repair. Visit MercNET, contact Mercury Marine customer
service, or your regional service center to determine whether repairs on a specific outboard within the affected serial number
range has been completed. As a Mercury Marine dealer, you should contact known affected customers to advise them of this
recall and schedule an appointment for the repair. A copy of the customer letter is included with this service bulletin for your
reference.

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

2018-10 OCTOBER 2018 © 2018 Mercury Marine Page 5 / 6

Start Relay Wire Abrasion—V‑8 200–300 and V‑6 175–225

Revised Production Exhaust Boot Clamp Installation

Current production outboards have been updated to provide enough clearance for removal of the start relay. The clamp has
been inverted from its original position with the threaded stud pointing aft, as shown. Additionally, the original torque
specification on the exhaust boot clamp locknuts is now obsolete. Each clamp must be installed by applying anti‑seize
compound to the threads of the clamp and tightening the nut with a 7/16 in. socket until the spring coils bind.

Tube Ref No. Description Where Used Part No.

81 Anti-Seize Compound Exhaust tube boot clamp threads 92-898101389

68165 68164

V-8 current production installation V-6 current production installation

Parts Required
Qty. Description Part Number
1 Corrugated conduit kit 8M0153113

Warranty
Mercury Marine will credit the dealer for the cost of parts and labor. Complete a warranty claim, listing:
• Outboard serial number
V‑8 Models (lower cowl removal not required)
• Labor: 0.5 hours
• Warranty flat rate code: SB05
• Part code: 399
• Fail code: 00
• Qty. 1 P/N 8M0153113
V‑6 Models (lower cowl removal required)
• Labor: 1.0 hour
• Warranty flat rate code: SB10
• Part code: 399
• Fail code: 00
• Qty. 1 P/N 8M0153113
United States and Canada: Complete/process the claim via MercNET or return a warranty claim form.
Outside the United States and Canada: Follow the instructions issued by the Marine Power International office or by an
authorized Marine Power distributor.

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

Page 6 / 6 © 2018 Mercury Marine OCTOBER 2018 2018-10

Dear Customer,

Thank you for purchasing a Mercury Marine V-8 or V-6 FourStroke outboard. We are dedicated
to providing a superior product of outstanding quality and reliability. On rare occasions, fulfilling
that commitment may require an additional step after you have taken ownership of the product.
We have discovered and wish to address an issue that requires attention. Please see the
information below, contact your dealer or service center and accept our apology for any
inconvenience this recall may cause.

What is the condition?

The outboard must have the start relay wiring harness routing inspected. The routing of the
harness may be incorrect, allowing the wires to contact the upper clamp on the exhaust tube
boot. The contact with the clamp could wear through the wire insulation and cause unintended
starter motor actuation. This starter actuation will not cause the outboard engine to start.

What will Mercury Marine do?

We have provided instructions to our dealers on the inspection and potential repositioning of the
exhaust tube clamp and start relay wiring harness to be performed on your outboard. This
update will be performed at no charge to you.

What should you do?

Contact your Mercury Marine outboard dealer to arrange a service appointment. When
scheduling your service appointment, mention Mercury Outboard Service Bulletin 2018-10.

Please present this notice to your Mercury Outboard dealer when you bring your engine
in for servicing.

What if you have other questions or if you no longer own this engine?
Please contact your Mercury Outboard dealer or call:

Mercury Marine—US, Canada 920 929 5040

Australia, Pacific + 61 3 9791 5822
Europe, Middle East, Africa + 32 87 32 32 11
Mexico, Central America, Caribbean,
+ 1 954 744 3500
South America
Asia, Singapore +65 6805 8100

We have sent this notice in the interest of your continued satisfaction with our product, and we
sincerely regret any inconvenience this recall may cause you.

Mercury Marine Service