Mercury Outboard Engine Service Manual

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6/8/9.9/10/15
6/8/9.9/10/15
90-827242R02 February 2003
Starting Model Year 1986
Starting Model Year 1986

Serial Number 0A197112 and Up (USA)
09503295 and Up (Belgium)
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Notice
Throughout this publication, Dangers, Warnings and Cautions (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.
DANGER
DANGER - Immediate hazards which WILL result in severe personal injury or death.
WARNING
WARNING - Hazards or unsafe practices which COULD result in severe personal
injury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
Notice to Users of This Manual

This service 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.
It is assumed that these personnel are familiar with the servicing procedures of these
products, or like or similar products manufactured and marketed by Mercury Marine, that
they have been trained in the recommended servicing procedures of these products which
includes 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 service trade of all conceivable procedures
by which a service might be performed and of the possible hazards and/or results of each
method. We have not undertaken any such wide evaluation. 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 by the
service procedure selected.
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.
It should be kept in mind, while working on the product, that the electrical system and ignition
system 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 which could enter the cylinders and
cause extensive internal damage when the engine is started.
90-827242R02 FEBRUARY 2003 Page i

It is important to note, 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 re-use, care should be
taken to select a replacement that matches the original.
Cleanliness and Care of Outboard Motor

A marine power product is a combination of many machined, honed, polished and lapped
surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any
product component is serviced, care and cleanliness are important. Throughout this
manual, 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 outboard which is suspended. Outboards should
be attached to work stands, or lowered to ground as soon as possible.
We reserve the right to make changes to this manual without prior notification.
Refer to dealer service bulletins for other pertinent information concerning the products
described in this manual.
Page ii 90-827242R02 FEBRUARY 2003

Service Manual Outline

Section 1 - General Information & Specifications
General Information
& Specifications 1
A - Specifications
B - Maintenance
C - General Information
D - Outboard Installation
Electrical and Ignition
2
Section 2 - Electrical and Ignition
A - Ignition System
B - Charging & Starting System
C - Timing/Synchronizing & Adjusting
Fuel System
3
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Delivery System
B - Emissions
Powerhead
4
Section 4 - Powerhead
Section 5 - Mid-Section
A - Clamp/Swivel Brackets and Driveshaft Housing
Mid-Section
5
B - Power Trim
Section 6 - Lower Unit
Section 7 - Attachments/Control Linkage
A - Throttle/Shift Linkage (Tiller Handle Shift Models)
Lower Unit
6
B - Throttle/Shift Linkage (Side Shift Models)
C - Tiller Handle
Section 8 - Manual Starter
Attachments/
Control Linkage 7
Manual Starter
8
90-827242R02 FEBRUARY 2003 Page iii

Propeller Information
For in-depth information on marine propellers and boat performance – written by marine
engineers – see your Authorized Dealer for the illustrated “What You Should Know About
Quicksilver Propellers... and Boat Performance Information” (Part No. 90-86144 92).
How To Use This Manual

The manual is divided into SECTIONS which represents major components and systems.
Some SECTIONS are further divided into PARTS. Each PART has a title page. A Table of
Contents for the particular PART is printed on the back of the title page.
SECTIONS and PARTS are listed on the Service Manual Outline sheet which immediately
follows the cover of this book.
Page Numbering
Two number groups appear at the bottom of each page. The example, below, is
self-explanatory.
EXAMPLE:
90-827242R1 MAY 1998 Page 2B-7
Revision No. 1 Section Number
Month of Printing Part of Section Letter
Year of Printing Page Number
Page iv 90-827242R02 FEBRUARY 2003

SPECIFICATIONS
GENERAL INFORMATION & SPECIFICATIONS 1

Section 1A – Specifications A
Table of Contents
General Specifications . . . . . . . . . . . . . . . . . . . 1A-1 Propeller Information Chart -9.9/10 HP . . . . . 1A-7
Propeller Information Chart - 6 HP . . . . . . . . . 1A-6 Propeller Information Chart -15 HP . . . . . . . . 1A-7
Propeller Information Chart - 8 HP . . . . . . . . . 1A-6 Mercury/Quicksilver Lubricants and Sealants 1A-8
General Specifications
Models 6/8/9.9/10/15
Model 6 4.5 (6)
Model 8 5.9 (8)
Model 8 Sailmate 5.9 (8)
PERFORMANCE Model 9.9 7.4 (9.9)
KW Model 9.9 Sailpower 7.4 (9.9)
(HP) XR/MAG/Viking10 7.5 (10)
Model Sea Pro/Marathon 10 7.5 (10)
Model 15 11.2 (15)
Model Sea Pro/Marathon 15 11.2 (15)
Manual Start
6 33.1 kg (73.0 lb)
8 33.1 kg (73.0 lb)
8 Sailmate 33.8 kg (74.5 lb)
9.9 33.8 kg (74.5 lb)
9.9 Sailpower 34.2 kg (76.5 lb)
XR/MAG/Viking10 33.8 kg (74.5 lb)
OUTBOARD Sea Pro/Marathon 10 33.8 kg (74.5 lb)
WEIGHT 15 34.0 kg (75.0 lb)
Sea Pro/Marathon 15 34.0 kg (75.0 lb)
Electric Start
6 36.1 kg (79.5 lb)
8 36.1 kg (79.5 lb)
9.9 36.7 kg (81.0 lb)
9.9 Sailpower 37.7 kg (83.0 lb)
15 37.0 kg (81.5 lb)
Recommended Gasoline Automotive Unleaded
with a Minimum Pump Posted
Octane Rating of 86
Recommended Oil 2 Cycle Outboard Oil
Ratio 25:1 (During break-in)
FUEL SYSTEM 50:1 (After break-in)
Fuel Tank Capacity
6/8/9.9/Sailpower, XR/MAG10 12.0 L, 2.7 Imp Gal., 3.2 U.S. Gal.
10 Sea Pro
Marathon/15 25.0 L, 5.5 Imp Gal., 6.6 U.S. Gal.
90-827242R02 FEBRUARY 2003 Page 1A-1

SPECIFICATIONS
Type Two-Stoke Cycle – Cross Flow

Displacement (1994 Model)
6 209 cc (12.8 cu. in.)
8 209 cc (12.8 cu. in.)
9.9 209 cc (12.8 cu. in.)
9.9 Sailpower 209 cc (12.8 cu. in.)
10 Sea Pro/Marathon 262 cc (16.0 cu. in.)
XR10/MAG10 262 cc (16.0 cu. in.)
CYLINDER
15 262 cc (16.0 cu. in.)
BLOCK
Displacement (1995 and Newer)
9.9 262 cc (16.0 cu. in.)
9.9 Sailpower 262 cc (16.0 cu. in.)
10 Sea Pro/Marathon 262 cc (16.0 cu. in.
XR/MAG/Viking 10 262 cc (16.0 cu. in.)
15 262 cc (16.0 cu. in.)
15 Sea Pro/Marathon 262 cc (16.0 cu. in.)
Diameter (Standard)(1994 Model)

6 53.975 mm (2.125 in.)
8 53.975 mm (2.125 in.)
8 Sailmate 53.975 mm (2.125 in.)
9.9 53.975 mm (2.125 in.)
9.9 Sailpower 53.975 mm (2.125 in.)
10 Sea Pro/Marathon 60.325 mm (2.375 in.)
XR/Mag 10 60.325 mm (2.375 in.)
CYLINDER 15 60.325 mm (2.375 in.)
BORE Diameter (Standard)(1995 Model)
9.9 60.325 mm (2.375 in.)
9.9 Sailpower 60.325 mm (2.375 in.)
XR/Mag/Viking 10 60.325 mm (2.375 in.)
15 60.325 mm (2.375 in.)
Taper/Out of Round Maximum 0.1016 mm (0.004 in.)
Bore Type Cast Iron
STROKE Length 45.7 mm (1.800 in.)
Top Main Bearing Journal 19.1 mm (0.7517 in.)
Center Main Bearing Journal 20.6 mm (0.8108 in.)
CRANKSHAFT Bottom Ball Bearing Journal 20.0 mm (0.7880 in.)
Connecting Rod Journal 20.6 mm (0.8125 in.)
Runout 0.076 mm (0.003 in.)
CONNECTING Piston Pin End (I.D.) 20.8 mm (0.8195 in.)
ROD Crankpin End (I.D.) 27.0 mm (1.0635 in.)
Piston Type Aluminum
PISTON Ring End Gap 0.25 mm - 0.46 mm
(0.010 in. - 0.018 in.)
Reed Stand Open (Maximum)
All Models 0.178 mm (0.007 in.)
REEDS
Reed Stop Opening (Maximum)
All Models 7.54 mm (0.296 in.)
Page 1A-2 90-827242R02 FEBRUARY 2003

SPECIFICATIONS
GEAR Gear Ratio 2.0:1

HOUSING Gearcase Capacity 200 ml (6.8 fl. oz.)
Lubricant Type Quicksilver Gear Lube Premium Blend
Forward Gear - Tooth count - Type 26 Spiral/Bevel
Pinion Gear - Tooth count - Type 13 Spiral/Bevel
Pinion Height Floating
Forward Gear Backlash No Adjustment
Reverse Gear Backlash No Adjustment
Water Pressure
With Thermostat
– @ W.O.T (5000 RPM) 34.5 - 48.3 kPa (5 - 7 PSI)
– @ Idle (750 RPM) 3.4 - 10.3 kPa (.5 – 1.5 PSI)
W/O Thermostat
– @ W.O.T (5000 RPM) 34.5 - 48.3 kPa (5 – 7 PSI)
– @ Idle (750 RPM) 0 - 7 kPa (0 – 1 PSI)
Transom Height Short Shaft 38 cm (15 in.)
Long Shaft 51 cm (20 in.)
Extra Long Shaft 63.5 cm (25 in.)
MID
Steering Pivot Range 78°
SECTION
Tilt Pin Positions 3 + 3 Shallow Water
Total Tilt Angle 78°
Allowable Transom Thickness 60.3 mm (2-3/8 in.)
Fuel Pre-Mixed Gasoline and Oil
Recommended Gasoline Automotive Lead-Free
Recommended Oil
2 Cycle Outboard Oil
FUEL Gasoline/Oil Ratio 25:1 (During Break-In)
SYSTEM 50:1 (After Break-In)
Fuel Tank Capacity
6/8/9.9/9.9 Sailpower 12.0 L, 3.2 U.S. Gal.
XR/MAG/10 Sea Pro/
Marathon/15 25.0 L, 6.6 U.S. Gal.
Manual Start Recoil
STARTING Electric Start 12 Volt
SYSTEM Starter Draw (Under Load) 55 Amperes
(No Load) 15 Amperes
Alternator Output
BLACK Stator - 2 Magnet Flywheel 4 Amp. (48 Watt)
CHARGING (8 Pole)(4 Pulses) @ 6000 RPM
SYSTEM
RED Stator - 4 Magnet Flywheel 6 amp (72 Watt)
(10 Pole)(5 Pulses) @ 6000 RPM
90-827242R02 FEBRUARY 2003 Page 1A-3

SPECIFICATIONS
Battery Rating 465 Marine Cranking Amps (MCA)

BATTERY
or 350 Cold Cranking Amps (CCA)
Type Capacitor Discharge
SPARK PLUG (1994)
6/8/9.9 NGK BP8H-N-10
10/15 NGK BP8HS-15
NGK BPZ8H-N-10*
SPARK PLUG GAP (1994)
6/8/9.9 1.0 mm (0.040 in.)
10/15 1.5 mm (0.060 in.)
SPARK PLUG (1995 AND NEWER)

6/8 NGK BP8H-N-10
9.9/10/15 NGK BP8HS-15
NGK BPZ8H-N-10*
SPARK PLUG GAP (1995 AND
IGNITION NEWER)
SYSTEM 6/8 1.0 mm (0.040 in.)
9.9/10/15 1.5 mm (0.060 in.)
Firing Order 1-2
Stator High Speed Winding 120 - 180 Ω (BLACK/WHITE -

GROUND)
Stator Low Speed Winding 3200 - 3800 Ω (BLACK/YELLOW -
Diode Test GROUND)
3100 – 3700 Ω (BLACK/YELLOW -
BLACK/WHITE)
Ignition Coil Resistance:
Primary 0.02 - 0.04 Ω
Secondary 8000 - 11000 Ω
Trigger 6500 - 8500 Ω
NOTE: *Use NGK-BPZ8H-N-10 where radio frequency interference (RFI) suppression is

required.
Page 1A-4 90-827242R02 FEBRUARY 2003

SPECIFICATIONS
Type Center Bowl, Integral Fuel Pump

Idle RPM (In Gear)
6 650 ± 75
8 725 ± 50
9.9/9.9 Sailpower 725 ± 50
10 Sea Pro/Marathon 850 ± 50
XR/MAG/Viking 10 725 ± 50
15 725 ± 50
Wide Open Throttle RPM
6 4000 – 5000
8 4500 – 5500
9.9/9.9 Sailpower 5000 – 6000
10 Sea Pro/Marathon 5000 – 6000
XR/MAG/Viking 10 5000 – 6000
15 5000 – 6000
Idle Mixture Screw (Initial Setting) Refer to Section 3 for Specifics
CARBURETOR
Float Setting (All Models) 25.4 mm (1 in.)
SPECIFICATIONS
Main Jet –
Thread size 10–32
1994 Model Year
6 .042
8 .046
9.9/9.9 Sailpower .052
10 Sea Pro/Marathon .064
XR/MAG 10 .052
15 .066
1995 and Newer
6 .042
8 .046
XR/MAG 10 .052
15/Viking 10 .072
Idle
6 8° BTDC ± 1°
8/8 Sailmate 8° BTDC ± 1°
9.9/9.9 Sailpower 8° BTDC ± 1°
TIMING 10 Sea Pro/Marathon 8° BTDC ± 1°
SPECIFICATIONS XR/MAG/Viking 10 8° BTDC ± 1°
15 8° BTDC ± 1°
15 Sea Pro/Marathon 8° BTDC ± 1°
Maximum BTDC @ 4500 RPM – All
Models 36° BTDC
90-827242R02 FEBRUARY 2003 Page 1A-5

SPECIFICATIONS
Propeller Information Chart - 6 HP

Wide Open Throttle RPM: 4000-5000
Recommended Transom Height: 15″, 20″, 25″
Right Hand Rotation Standard
Gear Reduction: 2:1
Diameter Pitch No. Of Material Typical Gross Typical Boat Speed Propeller Part
Blades Boat WGT. Length Range Number
(LBS) (MPH)
9″ 9″ 3 Alum. Up To 1400 Up To 15′ 10-19 48-828156A12
9″ 8″ 3 Alum. 1000 – 2200 12′ - 16′ 8-15 48-828154A12
9-1/4″ 7″ 3 Alum. 1200 – 2600 13′ - 17′ 5-12 48-828152A12
9-3/4″ 6-1/2″ 3 Alum. 1500+ High Reverse 3-10 48-828150A12
Thrust
9-3/4″ 5-1/2″ 3 Alum. 1900+ Workboat 1-8 48-828148A12
Thrust Hub: 42630 1 (Forward)

Propeller Drive Hub: 827598T
Diffuser Ring: 42594 (Aluminum)
Propeller Information Chart - 8 HP

Gear Reduction: 2:1
(LBS) (MPH)
9″ 9″ 3 Alum. Up To 1200 Up To 16′ 12-22 48-82815612
9″ 8″ 3 Alum. 1100 – 2000 14′ - 17′ 10-20 48-828154A12
9-1/4″ 7″ 3 Alum. 900 – 2400 14′ - 18′ 7-15 48-828152A12
Thrust
9-3/4″ 5-1/2″ 3 Alum. 1700+ Workboat 1-10 48-828148A12

Page 1A-6 90-827242R02 FEBRUARY 2003

SPECIFICATIONS
Propeller Information Chart -9.9/10 HP

Gear Reduction: 2:1
(LBS) (MPH)
9″ 9″ 3 Alum. Up To 1200 Up To 16′ 12-24 48-828156A12
9″ 8″ 3 Alum. 1100 – 2000 14′ - 17′ 12-22 48-828154A12
9-1/4″ 7″ 3 Alum. 900 – 2400 14′ - 18′ 8-18 48-828152A12
Thrust
9-3/4″ 5-1/2″ 3 Alum. 1700+ Workboat 1-13 48-828148A12

Propeller Information Chart -15 HP

Gear Reduction: 2:1
(LBS) (MPH)
9″ 10-1/2″ 3 Alum. Up To 1000 Up To 16′ 18-28 48-828158A12
9″ 9″ 3 Alum. 600 – 1500 14′ - 18′ 14-24 48-828156A12
9″ 8″ 3 Alum. 800 – 2400 15′ - 20′ 15-25 48-828154A12
9-1/4″ 7″ 3 Alum. 1000 – 3400 16′ - 22′ 8-18 48-828152A12
Thrust

90-827242R02 FEBRUARY 2003 Page 1A-7

SPECIFICATIONS
Mercury/Quicksilver Lubricants and Sealants

Tube Mercury Part Num- Quicksilver Part
Ref. No.
Description
ber Number
Needle Bearing As-
4 92-802868A1 N/A
sembly Lubricant
Dielectric Grease
6 92-823506-1 92-823506-1
Loctite 271 – Thread

7 92-809819 92-809819
Locker
Loctite 567 PST Pipe
9 92-809822 92-809822
Sealant
Loctite Master Gasket
12 92-12564-2 92-12564-2
Kit
2 Cycle Premium Out-
14 92-802813A1 92-802813Q1
board Oil
19 Perfect Seal 92-34227-1 92-34227-1
25 Liquid Neoprene 92-25711-3 92-25711-3
27 Bellows Adhesive N/A 92-86166Q1

Loctite 680 Retaining
33 92-809833 92-809833
Compound
34 Special Lubricant 101 92-802865A1 92-802865Q1
U-Joint and Gimbal 92-802870A1 92-802870Q1
42
Bearing Grease
Loctite 222 Thread
51 92-809818 92-809818
Locker
Loctite 242 Thread
66 92-809821 92-809821
Locker
4 Cycle 25W40 Engine
79 92-802837A1 92-802837Q1
Oil
Premium Gear Lubri-
82 92-802846A1 92-802846Q1
cant
High Performance 92-802854A1 92-802854Q1
87
Gear Lube
Engine Coupler Spline
91 92-802869A1 92-802869Q1
Grease
94 Anti-Corrosion Grease 92-802867A1 92-802867Q1
95 2-4-C with Teflon 92-802859A1 92-802859Q1
4 Stroke 10W30 Out-
110 92-802833A1 92-802833Q1
board Oil
Power Trim & Steering
114 92-802880A1 92-802880Q1
Fluid
Page 1A-8 90-827242R02 FEBRUARY 2003

SPECIFICATIONS

Ref. #
Description
ber Number
Premium Plus 2 Cycle
115
TC-W3 Outboard Oil 92-802824A1 92-802824Q1
RTV 587 Silicone
116 92-809825 92-809825
Sealer
117 Loctite 7649 Primer N 92-809824 92-809824
Storage Seal Rust In- 92-802878-56 92-802878Q56
119
hibitor
120 Corrosion Guard 92-802878 55 92-802878Q55
15W40 4-cycle Diesel 92-877695K1 92-877695Q1
121
Engine Oil
Extended Life Anti- 92-877770K1 92-877770K1
122
freeze/Coolant
123 Marine Engine Coolant NA 92-813054A2
Fuel System Treat-
124 ment and Stabilizer 92-802876A1 92-802876Q1
Concentrate
Heat Transfer Com- 92-805701 1
125
pound
126 Liquid Gasket 92-808137 NA
127 T442 Sealant 92-862258 NA

Loctite 5900 Ultra 92-809826 NA
128 Black RTV Silicone
Sealant
Loctite Gasket Remov- 92-809828 1 NA
129
er
Sealer Kit, Two Part NA 92-65150 1
130
Epoxy
131 Anti-seize Compound 92-881091K1
132 Torco MTF Gear Oil 92–849864–1
Optimol Longtime PD 92–848767
133
2
Dexron III Automatic Obtain Locally Obtain Locally
134
Transmission Fluid
135 Loctite 592 Obtain Locally Obtain Locally
136 Loctite Quick Tite Obtain Locally Obtain Locally
137 Isopropyl Alcohol Obtain Locally Obtain Locally
138 Hot Glue Obtain Locally Obtain Locally
1
90-827242R02 FEBRUARY 2003 Page 1A-9

SPECIFICATIONS

Ref. #
Description
ber Number
Cyanacrylate Adhe-
1
141 Obtain Locally Obtain Locally
sive
3M Permabond
142 Obtain Locally Obtain Locally
#3M08155
Loctite 598 RTV Seal- Obtain Locally Obtain Locally
145
ant
146 Insulating Compound 92–41669–1
Page 1A-10 90-827242R02 FEBRUARY 2003

MAINTENANCE

Section 1B – Maintenance B
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 1B-1 Fuse Replacement – Electric Start Remote
Gearcase Lubricant Capacity . . . . . . . . . . . . . 1B-2 Control Models . . . . . . . . . . . . . . . . . . . . . . . . . 1B-7
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . 1B-8
Inspection and Maintenance Schedule . . . . . 1B-3 Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . 1B-10
Before Each Use . . . . . . . . . . . . . . . . . . . . . 1B-3 Gearcase Lubricant Capacity . . . . . . . . . . 1B-10
After Each Use . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Draining Gearcase . . . . . . . . . . . . . . . . . . . 1B-10
Every 100 Hours of Use or Once Yearly, Checking Lubricant Level and Refilling
Whichever Occurs First . . . . . . . . . . . . . . . 1B-3 Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-11
Every 300 Hours of Use or Three Years . 1B-3 Storage Preparations . . . . . . . . . . . . . . . . . . . . 1B-12
Flushing The Cooling System . . . . . . . . . . . . . 1B-4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5 Protecting External Engine Components 1B-12
Fuel Line Inspection . . . . . . . . . . . . . . . . . . 1B-5 Protecting Internal Engine Components . 1B-12
Engine Fuel Filter . . . . . . . . . . . . . . . . . . . . 1B-5 Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Corrosion Control Anode . . . . . . . . . . . . . . . . . 1B-6 Positioning Outboard for Storage . . . . . . . 1B-13
Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . 1B-6 Battery Storage . . . . . . . . . . . . . . . . . . . . . . 1B-13
Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . 1B-7
90-827242R02 FEBRUARY 2003 Page 1B-1

MAINTENANCE
Gearcase Lubricant Capacity

Gear Case Ratio Capacity
2.00:1 200.0 ml (6.8 fl. oz.)
Special Tools
1. Flushing attachment 12612Q2
2. Grease gun 91-37299Q2
Page 1B-2 90-827242R20 FEBRUARY 2003

MAINTENANCE
Inspection and Maintenance Schedule

Before Each Use
1. Check that lanyard stop switch stops the engine.
2. Visually inspect the fuel system for deterioration or leaks.
3. Check outboard for tightness on transom.
4. Check steering system for binding or loose components.
5. Visually check steering link rod fasteners for proper tightness.
6. Check propeller blades for damage.
After Each Use
1. Flush out the outboard cooling system if operating in salt or polluted water.
2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase
with fresh water if operating in salt water.
Every 100 Hours of Use or Once Yearly, Whichever Occurs First
1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.
2. Inspect and clean spark plugs.
3. Check fuel line filter for contaminants.
4. Check carburetor adjustments, if required.
5. Check corrosion control anodes. Check more frequently when used in salt water.
6. Drain and replace gearcase lubricant.
7. Lubricate splines on the drive shaft.∗
8. Electric start models – Inspect battery.
9. Remote control models – Check control cable adjustments. ∗
10. Remove engine deposits with Power Tune Engine Cleaner.
11. Check tightness of bolts, nuts, and other fasteners.
12. Clean fuel tank pick up filter.
Every 300 Hours of Use or Three Years
1. Replace water pump impeller (more often if overheating occurs or reduced water
pressure is noted).*
∗ These items should be serviced by an authorized dealer.
90-827242R02 FEBRUARY 2003 Page 1B-3

MAINTENANCE
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.
Use a Quicksilver accessory or equivalent flushing attachment.
WARNING
To avoid possible injury when flushing, remove the propeller. Refer to Propeller
Replacement.
1. Remove propeller (refer to Propeller Replacement). Install the flushing attachment so
the rubber cups fit tightly over the cooling water intake holes.
CAUTION
Never start or run your outboard (even momentarily) without water circulating
through the cooling water intake in the gearcase to prevent damage to the water
pump (running dry) or overheating of the engine.
2. Attach a water hose to the flushing attachment. Turn on the water and adjust the flow
so water is leaking around the rubber cups to ensure the engine receives an adequate
supply of cooling water.
3. Start the engine and run it at idle speed in neutral shift position.
4. Adjust water flow if necessary so excess water continues leaking out from around the
rubber cups to ensure the engine is receiving an adequate supply of cooling water.
5. Check for a steady stream of water flowing out of the water pump indicator hole.
Continue flushing the outboard for 3 to 5 minutes, carefully monitoring water supply at
all times.
6. Stop the engine, turn off the water, and remove the flushing attachment. Reinstall the
propeller.
Page 1B-4 90-827242R20 FEBRUARY 2003

MAINTENANCE
Fuel System
WARNING
Avoid serious injury or death from gasoline fire or explosion. Carefully follow all
fuel system service instructions. Always stop the engine and DO NOT smoke or
allow open flames or sparks in the area while servicing any part of the fuel system.
Before servicing any part of the fuel system, stop engine and disconnect the battery. Drain
the fuel system completely. Use an approved container to collect and store fuel. Wipe up
any spillage immediately. Material used to contain spillage must be disposed of in an
approved receptacle. Any fuel system service must be performed in a well ventilated area.
Inspect any completed service work for sign of fuel leakage.
Fuel Line Inspection
Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness or other
signs of deterioration or damage. If any of these conditions are found, the fuel line or primer
bulb must be replaced.
Engine Fuel Filter
Inspect the sight bowl for water accumulation and inspect the filter element for sediment.
Clean filter as follows.
REMOVAL
1. Hold onto the filter cover cover to prevent it from turning.
2. Turn off the sight bowl.
3. Pull out the filter element and wash it with cleaning solvent.
INSTALLATION
4. Push the open end of the filter element, into cover.
5. Place the O-ring seal into the sight bowl and screw the sight bowl hand tight into the
cover.
b
c
d
a - Filter cover
b - Filter
c - O-ring
d - Sight bowl
6. Visually inspect for fuel leakage around the sight bowl by squeezing the primer bulb until
firm, forcing fuel into the sight bowl.
90-827242R02 FEBRUARY 2003 Page 1B-5

MAINTENANCE
Corrosion Control Anode

The outboard has a corrosion control anode installed to the gear case. An anode helps
protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded
instead of the outboard metals.
1. The anode requires periodic inspection especially in salt water 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.
a - Anode
Spark Plug Inspection

Inspect spark plugs at the recommended intervals.
1. Remove the spark plug leads by twisting the rubber boots slightly and pull off.
2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn
or the insulator is rough, cracked, broken, blistered or fouled.
3. Set the spark plug gap. See Specification Chart in General Information Section.
4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs
finger tight, and tighten 1/4 turn or torque to 27 N·m (20 lb. ft.).
Page 1B-6 90-827242R20 FEBRUARY 2003

MAINTENANCE
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. Add water as necessary to keep the battery full.
3. Make sure the battery is secure against movement.
4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive
and negative to negative.
5. Make sure the battery is equipped with a nonconductive shield to prevent accidental
shorting of battery terminals.
Fuse Replacement – Electric Start Remote Control Models

The electric starting circuit is protected from overload by a SFE 20 AMP fuse. If the fuse is
blown, the electric starter motor will not operate. Locate and correct the cause of the
overload. If the cause is not found, the fuse may blow again. Replace the fuse with a fuse
of the same rating.
1. Replace with a new SFE 20 AMP fuse.
a
a - SFE 20 amp fuse
90-827242R02 FEBRUARY 2003 Page 1B-7

MAINTENANCE
Lubrication Points
1. Lubricate the following with 2-4-C with Teflon or Special Lubricant 101.
• Tilt tube.
• Transom clamp screws.
• Swivel bracket.
• Steering friction adjustment shaft (tiller handle models).
a - Swivel bracket
b - Steering friction adjustment shaft
Page 1B-8 90-827242R20 FEBRUARY 2003

MAINTENANCE
• Tilt lock pins (Make sure this pin is free to push in and out).
• Lubricate along the entire tilt pin track on both transom brackets.
a
a
a - Tilt lock pins

b - Tilt pin track
• Lubricate the throttle and shaft cables, moving components and pivot locations.
WARNING
The end of the steering cable must be fully retracted into the outboard tilt tube
before adding lubricant. Adding lubricant to steering cable when fully extended
could cause steering cable to become hydraulically locked. An hydraulically locked
steering cable will cause loss of steering control, possibly resulting in serious
injury or death.
• Rotate steering wheel (if so equipped) to fully retract the steering cable end into
the outboard tilt tube. Lubricate steering cable through grease fitting and cable
end.
a b
a - Grease fitting
b - Steering cable end
90-827242R02 FEBRUARY 2003 Page 1B-9

MAINTENANCE
2. Lubricate the following with light weight oil.

• Steering Link Rod Pivot Points.
3. Lubricate the following with anti-corrosion grease or 2-4-C with Teflon.

• Coat the entire propeller shaft with lubricant to prevent the propeller hub from
corroding to the shaft.
Gearcase Lubrication
Gearcase Lubricant Capacity
Gear Case Ratio Capacity
2.00:1 200.0 ml (6.8 fl. oz.)
Draining Gearcase
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.
Whenever you remove the fill/drain plug, examine the magnetic end for metal particles. A
small amount of metal filings or fine 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.
Page 1B-10 90-827242R20 FEBRUARY 2003

MAINTENANCE
1. Place outboard in a vertical operating position.

2. Place drain pan below outboard.
3. Remove fill/drain plug and vent plug and drain lubricant.
bb
a - Fill/Drain Plug
b - Vent plug
Checking Lubricant Level and Refilling Gearcase

1. Place outboard in a vertical operating position.
2. Remove vent plug from vent hole.
3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole.
4. Stop adding lubricant. Install the vent plug and sealing washer before removing the
lubricant tube.
a - Fill/Drain plug
b - Vent plug
5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.
90-827242R02 FEBRUARY 2003 Page 1B-11

MAINTENANCE
Storage Preparations
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.
Fill the fuel system (tank, hoses, fuel pumps, and fuel injection systems) with treated
(stabilized) fuel to help prevent formation of varnish and gum. Proceed with following
instructions.
1. Portable fuel tank – Pour the required amount of fuel system/stabilizer concentrate
(follow instructions on container) into fuel tank. Tip fuel tank back and forth to mix
stabilizer with the fuel.
2. Permanently Installed Fuel Tank – Pour the required amount of fuel system/stabilizer
concentrate (follow instructions on container) into a separate container and mix with
approximately one liter (one quart) of gasoline. Pour mixture into fuel tank.
3. Place the outboard in water or connect flushing attachment. Run the engine for ten
minutes to allow treated fuel to fill the fuel system.
Protecting External Engine Components
1. Lubricate all outboard components listed in the Inspection and Maintenance Schedule.
2. Touch up any paint nicks.
3. Spray Corrosion Guard on external metal surfaces (except corrosion control anodes).
Protecting Internal Engine Components
NOTE: Before performing Steps 1 and 2, make sure the fuel system has been prepared for
storage.
1. Place the outboard in water or connect flushing attachment. Start the engine and let it
run in neutral to warm up.
2. With engine running at fast idle, stop the fuel flow by disconnecting the remote fuel line.
When engine begins to stall, quickly spray Storage Seal Rust Inhibitor into carburetor
until engine stops from lack of fuel.
3. Remove the spark plugs and inject a five second spray of Storage Seal Rust Inhibitor
around the inside of each cylinder.
4. Rotate the flywheel manually several times to distribute the Storage Seal in the
cylinders. Reinstall spark plugs.
Gearcase
Drain and refill the gearcase lubricant. Refer to Refilling Gearcase
Page 1B-12 90-827242R20 FEBRUARY 2003

MAINTENANCE
Positioning Outboard for Storage

Store outboard in an upright position to allow water to drain out of outboard.
CAUTION
If outboard is stored tilted up in freezing temperature, trapped cooling water or rain
water that may have entered the propeller exhaust outlet in the gearcase could
freeze and cause damage to the outboard.
Battery Storage
1. Follow the battery manufacturers instructions for storage and recharging.
2. Remove the battery from the boat and check water level. Recharge if necessary.
3. Store the battery in a cool, dry place.
4. Periodically check the water level and recharge the battery during storage.
90-827242R02 FEBRUARY 2003 Page 1B-13

GENERAL INFORMATION

Section 1C – General Information C
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 1C-1 Propeller Selection . . . . . . . . . . . . . . . . . . . . . . 1C-6
Serial Number Location . . . . . . . . . . . . . . . . . . 1C-1 Propeller Removal/Installation . . . . . . . . . . . . 1C-7
Conditions Affecting Performance . . . . . . . . . 1C-2 Compression Check . . . . . . . . . . . . . . . . . . . . . 1C-9
Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Painting Procedures . . . . . . . . . . . . . . . . . . . . . 1C-9
Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-3 Cleaning & Painting Aluminum Propellers
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 & Gear Housings . . . . . . . . . . . . . . . . . . . . 1C-9
Following Complete Submersion . . . . . . . . . . 1C-5 Decal Application . . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Submerged While Running . . . . . . . . . . . . 1C-5 Decal Removal . . . . . . . . . . . . . . . . . . . . . . . 1C-11
Fresh Water Submersion . . . . . . . . . . . . . . 1C-5 Instructions for Wet Application . . . . . . . . . 1C-11
Salt Water Submersion . . . . . . . . . . . . . . . . 1C-5
Serial Number Location

The Outboard serial number is located on the lower starboard side of the engine block. A
serial number is also located on the starboard side of the swivel bracket.
a
OGXXXXXX
19XX b
XXXX
c
e
d
XX
a - Serial number
b - Model year
c - Model description
d - Year manufactured
e - Certified Europe insignia
90-827242R02 FEBRUARY 2003 Page 1C-1

GENERAL INFORMATION
Conditions Affecting Performance

Weather
Rated hp
Horsepower Loss
Due to Atmosphere
Conditions
Summer hp
Secondary Loss Due to
Propeller Becoming To Large
for Summer Horsepower
RPM Drop
Due to Weather
ENGINE RPM Rated RPM
It is a known fact that weather conditions exert a profound effect on power output of internal
combustion engines. Therefore, established horsepower ratings refer to the power that the
engine will produce at its rated RPM under a specific combination of weather conditions.
Corporations internationally have settled on adoption of I.S.O. (International Standards
Organization) engine test standards, as set forth in I.S.O. 3046 standardizing the
computation of horsepower from data obtained on the dynamometer. All values are
corrected to the power that 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 or 5 Km per-hour (2 or 3 miles-per-hour) in some cases. (Refer to previous chart.)
Nothing will regain this speed for the boater, but the coming of cool, dry weather.
In pointing out the practical consequences of weather effects, an engine--running on a hot,
humid summer day--may encounter a loss of as much as 14% of the horsepower it would
produce on a dry, brisk spring or fall day. The horsepower, that any internal combustion
engine produces, depends upon the density of the air that it consumes, and in turn, this
density is dependent upon the temperature of the air, its barometric pressure and water
vapor (or humidity) content.
Accompanying this weather-inspired loss of power is a second but more subtle loss. At
rigging time in early spring, the engine was equipped with a propeller that allowed the engine
to turn within its recommended RPM range at full throttle. With the coming of the summer
weather and the consequent drop in available horsepower, this propeller will, in effect,
become too large. Consequently, the engine operates at less than its recommended RPM.
Page 1C-2 90-827242R02 FEBRUARY 2003

GENERAL INFORMATION
Due to the horsepower/RPM characteristics of an engine, this will result in further loss of
horsepower at the propeller with another decrease in boat speed. This secondary loss,
however, can be regained by switching to a smaller pitch propeller that allows the engine
to again run at recommended RPM.
For boaters to realize optimum engine performance under changing weather conditions, it
is essential that the engine have the proper propeller to allow it to operate at or near the top
end of the recommended maximum RPM range at wide-open-throttle with a normal boat
load.
Not only does this allow the engine to develop full power, but equally important is the fact
that the engine also will be operating in an RPM range that discourages damaging
detonation. This, of course, enhances overall reliability and durability of the engine.
Boat
WEIGHT DISTRIBUTION
1. Proper positioning of the weight inside the boat (persons and gear) has a significant
effect on the boat’s performance, for example:
a. Shifting weight to the rear (stern)
(1.) Generally increases top speed.
(2.) If in excess, can cause the boat to porpoise.
(3.) Can make the bow bounce excessively in choppy water.
(4.) Will increase the danger of the following - wave splashing into the boat when
coming off plane.
b. Shifting weight to the front (bow)
(1.) Improves ease of planing off.
(2.) Generally improves rough water ride.
(3.) If excessive, can make the boat veer left and right (bow steer).
BOTTOM
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.
1. 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.
2. 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.
3. 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 through hull fasteners be coated with a quality marine sealer at time
of installation. Water intrusion into the transom core and/or inner hull will result in additional
boat weight (reduced boat performance), hull decay and eventual structural failure.
90-827242R02 FEBRUARY 2003 Page 1C-3

GENERAL INFORMATION
CAVITATION
Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on
the gear case or from an irregularity in the propeller blade itself. These vapor bubbles flow
back and collapse when striking the surface of the propeller blade resulting in the erosion
of the propeller blade surface. If allowed to continue, eventual blade failure (breakage) will
occur.
Engine
DETONATION
Detonation in a 2-cycle engine resembles the pinging heard in an automobile engine. It can
be otherwise described as a tin-like rattling or plinking sound.
Detonation is an explosion of an unburned portion of the fuel/air charge after the spark plug
has fired. Detonation creates severe shock waves in the engine, and these shock waves
often find or create a weakness: The dome of a piston, cylinder head/gasket, piston rings
or piston ring lands, piston pin and roller bearings.
A few of the most common causes of detonation in a marine 2-cycle application are as
follows:
• Over-advanced ignition timing.
• Use of low octane gasoline.
• Propeller pitch too high (engine RPM below recommended maximum range).
• Lean fuel mixture at or near wide-open-throttle.
• Spark plugs (heat range too hot - incorrect reach - cross-firing).
• Inadequate engine cooling (deteriorated cooling system).
• Combustion chamber/piston deposits (result in higher compression ratio).
Detonation usually can be prevented if:
1. The engine is correctly set up.
2. Diligent maintenance is applied to combat the detonation causes.
51115
Damaged Piston Resulting from Detonation
Page 1C-4 90-827242R02 FEBRUARY 2003

GENERAL INFORMATION
Following Complete Submersion

Submerged While Running
When an engine is submerged while running, the possibility of internal engine damage is
greatly increased. If, after engine is recovered and with spark plugs removed, engine fails
to turn over freely when turning flywheel, the possibility of internal damage (bent connecting
rod and/or bent crankshaft) exists. If this is the case, the powerhead must be disassembled.
Fresh Water Submersion
1. Recover engine as quickly as possible.
2. Remove cowling.
3. Flush exterior of outboard with fresh water to remove mud, weeds, etc. DO NOT attempt
to start engine if sand has entered powerhead, as powerhead will be severely damaged.
Disassemble powerhead if necessary to clean components.
4. Remove spark plugs and get as much water as possible out of powerhead. Most water
can be eliminated by placing engine in a horizontal position (with spark plug holes down)
and rotating flywheel.
5. Pour alcohol into carburetor throats (alcohol will absorbed water). Again rotate flywheel.
6. Turn engine over and pour alcohol into spark plug openings and rotate flywheel.
7. Turn engine over (place spark plug openings down) and pour engine oil into throat of
carburetors while rotating flywheel to distribute oil throughout crankcase.
8. Again turn engine over and pour approximately one teaspoon of engine oil into each
spark plug opening. Again rotate flywheel to distribute oil in cylinders.
9. Remove and clean carburetors and fuel pump assembly.
10. Dry all wiring and electrical components using compressed air.
11. Disassemble the engine starter motor and dry the brush contacts, armature and other
corrodible parts.
12. Reinstall spark plugs, carburetors and fuel pump.
13. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for
at least one hour to eliminate any water in engine.
14. If engine fails to start, determine cause (fuel, electrical or mechanical). Engine should
be run within 2 hours after recovery of outboard from water, or serious internal damage
may occur. If unable to start engine in this period, disassemble engine and clean all
parts. Apply oil as soon as possible.
Salt Water Submersion
Due to the corrosive effect of salt water on internal engine components, complete
disassembly is necessary before any attempt is made to start the engine.
90-827242R02 FEBRUARY 2003 Page 1C-5

GENERAL INFORMATION
Propeller Selection
For in-depth information on marine propellers and boat performance see your Authorized
Dealer for the illustrated What You Should Know About Quicksilver Propellers... and
Boat Performance Information (Part No. 90-86144 92).
For best all around performance from your outboard/boat combination, select a propeller
that allows the engine to operate in the upper half of the recommended full throttle RPM
range with the boat normally loaded (refer to Section 1A - Specifications). This RPM range
allows for better acceleration while maintaining maximum boat speed.
If changing conditions cause the RPM to drop below the recommended range (such as
warmer, more humid weather, operation at higher elevations, increased boat load or a dirty
boat bottom/gear case) a propeller change or cleaning may be required to maintain
performance and ensure the outboard’s durability.
Check full-throttle RPM using an accurate tachometer with the engine trimmed out to a
balanced-steering condition (steering effort equal in both directions) without causing the
propeller to break loose.
Refer to Mercury Precision Parts/Quicksilver Accessory Guide for a complete list of
available propellers.
1. Select a propeller that will allow the engine to operate at or near the top of the
recommended full throttle RPM range (refer to Section 1A - Specifications preceding)
with a normal load. Maximum engine speed (RPM) for propeller selection exists when
boat speed is maximum and trim is minimum for that speed. (High RPM, caused by an
excessive trim angle, should not be used in determining correct propeller.) Normally,
there is a 150-350 RPM change between propeller pitches.
2. If full throttle operation is below the recommended range, the propeller must be changed
to one with a lower pitch to prevent loss of performance and possible engine damage.
3. After initial propeller installation, the following common conditions may require that the
propeller be changed to a lower pitch:
a. Warmer weather and great humidity will cause an RPM loss.
b. Operating in a higher elevation causes an RPM loss.
c. Operating with a damaged propeller or a dirty boat bottom or gear housing will cause
an RPM loss.
d. Operation with an increased load (additional passengers, equipment, pulling skiers,
etc.).
Page 1C-6 90-827242R02 FEBRUARY 2003

GENERAL INFORMATION
Propeller Removal/Installation
WARNING
If the propeller shaft is rotated while the engine is in gear, there is the possibility that
the engine will crank over and start. To prevent this type of accidental engine
starting and possible serious injury caused from being struck by a rotating
propeller, always shift outboard to neutral position and remove spark plug leads
when you are servicing the propeller.
1. Shift outboard to neutral position.
N
N
2. Remove the spark plug leads to prevent engine from starting.

3. Place a block of wood between gear case and propeller to hold propeller and remove
propeller nut.
4. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed,
have the propeller removed by an authorized dealer.
5. Coat the propeller shaft with Anti-Corrosion Grease or 2-4-C with Teflon.
IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller
shaft, especially in salt water, 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.
90-827242R02 FEBRUARY 2003 Page 1C-7

GENERAL INFORMATION
6. Install forward thrust hub, propeller, rear thrust hub and propeller nut onto the shaft.
d c
b a
a - Forward thrust hub
b - Propeller
c - Rear thrust hub
d - Propeller nut
7. Place a block of wood between gear case and propeller and tighten propeller nut.
Page 1C-8 90-827242R02 FEBRUARY 2003

GENERAL INFORMATION
Compression Check
Normal Compression (All Models) 787 – 856 kPa (115 – 125 psi)
1. Remove spark plugs.

2. Install compression gauge in spark plug hole.
3. Hold throttle plate at W.O.T.
4. Crank the engine over until the compression reading peaks.
5. Check and record compression of each cylinder. The difference in compression
readings between each cylinder should not vary more than 15%. If compression varies
by more than 15% or compression for both cylinders is less than 685kPa (100psi), the
powerhead should be disassembled and inspected.
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. Cylinder scoring: If powerhead shows any indication of overheating, such as discolored
or scorched paint, visually inspect cylinders for scoring or other damage. Refer to
Section 4 Powerhead.
Painting Procedures
Cleaning & Painting Aluminum Propellers & Gear Housings
WARNING
Avoid serious injury from flying debris. Avoid serious injury from airborne
particles. Use eye and breathing protection with proper ventilation.
PROPELLERS
1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch-Brite,
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’s Light Gray Primer.
5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish
coat.
6. Apply the finish coat using Mercury/Quicksilver’s EDP Propeller Black.
90-827242R02 FEBRUARY 2003 Page 1C-9

GENERAL INFORMATION
GEAR HOUSINGS
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 that 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.
Procedure:
1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine
growth, and rinse with water, if necessary.
2. Wash gear housing with soap and water, then rinse.
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 (DX-330) wax and grease remover.
5. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment.
IMPORTANT: Do not use any type of 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 (DP-90LF) with equal part catalyst (DP-402LF) per
manufacturers instructions, allowing 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 top coating
assemblies.
8. Use Ditzler Urethane DU9300 for Mercury Black, DU34334 for Mariner Grey, and
DU35466 for Force Charcoal, and DU33414 for Sea Ray White. Catalyze all three colors
with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents per Ditzler label.
CAUTION
Be sure to comply with instructions on the label for ventilation and respirators.
Using a spray gun, apply one half to one mil even film thickness. Let dry, flash off
for five minutes and apply another even coat of one half to one mil film thickness.
This 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 sacrificial zinc trim tab or zinc 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.
Page 1C-10 90-827242R02 FEBRUARY 2003

GENERAL INFORMATION
Decal Application
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.
Instructions for Wet Application
NOTE: The following decal installation instructions are provided for a wet installation. All
decals should be applied wet.
TOOLS REQUIRED
1. Plastic Squeegee*
2. Stick Pin
3. Dish Washing liquid detergent without ammonia. Do not use a soap that contains
petroleum based solvents.
** Automotive body filler squeegee.
SERVICE TIP: Placement of decals using the wet application will allow time to
position decal. Read entire installation instructions on this technique before
proceeding.
TEMPERATURE
IMPORTANT: Installation of vinyl decals should not be attempted while in direct
sunlight. Air and surface temperature should be between 15°C (60°F) and 38°C
(100°F) for best application.
SURFACE PREPARATION
IMPORTANT: Do not use a soap or any petroleum based solvents to clean application
surface.
Clean entire application surface with mild dish washing liquid and water. Rinse surface
thoroughly with clean water.
90-827242R02 FEBRUARY 2003 Page 1C-11

GENERAL INFORMATION
DECAL APPLICATION
1. Mix 16 ml (1/2 ounce) of dish washing liquid in 4 literes (1 gallon) of cool water to use
as wetting solution.
NOTE: Leave protective masking, if present, on the face of decal until final steps of decal
installation. This will ensure that the vinyl decal keeps it’s shape during installation.
2. Place the decal face down on a clean work surface and remove the paper backing from
adhesive side of decal.
3. Using a spray bottle, flood the entire adhesive side of the decal with the pre-mixed
wetting solution.
4. Flood area where the decal will be positioned with wetting solution.
5. Position pre-wetted decal on wetted surface and slide into position.
6. Starting at the center of the decal, lightly squeegee out the air bubbles and wetting
solution with overlapping strokes to the outer edge of the decal. Continue going over the
decal surface until all wrinkles are gone and adhesive bonds to the cowl surface.
7. Wipe decal surface with soft paper towel or cloth.
8. Wait 10 - 15 minutes.
9. Starting at one corner, carefully and slowly pull the masking off the decal surface at a
180° angle.
NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with
stick pin and press out the entrapped air or wetting solution with your thumb (moving toward
the puncture).
Page 1C-12 90-827242R02 FEBRUARY 2003

OUTBOARD INSTALLATION

Section 1D – Outboard Installation D
Table of Contents
Notice to Installer and Owner . . . . . . . . . . . . . 1D-1 Steering Cable Seal . . . . . . . . . . . . . . . . . . 1D-4
Boat Horsepower Capacity . . . . . . . . . . . . . . . 1D-1 Steering Link Rod Installation . . . . . . . . . . 1D-5
Outboard Remote Control . . . . . . . . . . . . . 1D-2 Remote Control Installation . . . . . . . . . . . . . . . 1D-7
Selecting Accessories For The Outboard 1D-2 Shift and Throttle Cable Installation to
Selecting Steering Cables and Remote the Outboard . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-7
Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . 1D-2 Remote Wiring Harness Connection
Installing Outboard . . . . . . . . . . . . . . . . . . . . . . 1D-3 to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-13
Steering Cable and Steering Link Rod Battery Cable Connections . . . . . . . . . . . . . . . 1D-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Tilt Pin Adjustment . . . . . . . . . . . . . . . . . . . . . . 1D-15
Installing Ride Guide Steering Cable to Placing Tilt Pin in Lower Holes . . . . . . . . . 1D-15
the Outboard . . . . . . . . . . . . . . . . . . . . . . . . 1D-3 Placing Tilt Pin in Upper Holes . . . . . . . . . 1D-15
Notice to Installer and Owner

This manual as well as safety labels posted on the outboard use the following safety alerts
to draw your attention to special safety instructions that should be followed.
DANGER
DANGER – Immediate hazards which will result in severe personal injury or death.
WARNING
WARNING – Hazards or unsafe practices which could result in severe personal
injury or death.
CAUTION
CAUTION – Hazards or unsafe practices which could result in minor injury or
product or property damage.
Boat Horsepower Capacity

U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
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.
90-827242R02 FEBRUARY 2003 Page 1D-1

WARNING
Using an outboard that exceeds the maximum horsepower limit of a boat can: 1)
cause loss of boat control 2) place too much weight at the transom altering the
designed flotation characteristics of the boat or 3) cause the boat to break apart
particularly around the transom area. Overpowering a boat can result in serious
injury, death, or boat damage.
Outboard Remote Control

The remote control connected to your outboard must be equipped with a start in gear
protection device. This prevents the engine from starting when the outboard is in gear.
WARNING
Avoid serious injury or death from a sudden unexpected acceleration when starting
your engine. The design of this outboard requires that the remote control used with
it must have a built in start in gear protection device.
Selecting Accessories For The Outboard

Mercury Marine Quicksilver Accessories have been specifically designed and tested for
your outboard.
Mercury Marine Quicksilver accessories are available from Mercury Marine dealers.
Some accessories not manufactured or sold by Mercury Marine are not designed to be
safely used with your outboard or outboard operating system. Acquire and read the
installation, operation, and maintenance manuals for all your selected accessories.
Selecting Steering Cables and Remote Control Cables

Install steering mount and steering wheel in accordance with installation instructions that
accompany each.
IMPORTANT: Steering cable must be correct length. Sharp bends on too-short of a
cable result in kinks; too-long of a cable require unnecessary bends and/or loops.
Both conditions place extra stress on the cable.
Refer to Mercury Precision Parts/Quicksilver Accessories Guide to determine correct
length of steering cable.
Page 1D-2 90-827242R02 FEBRUARY 2003

Installing Outboard
1. Measure the transom height of your boat. The boat bottom should be aligned or be within
25 mm (1 in.) above the anti-ventilation plate of the outboard.
2. Place outboard on center line of transom.
0 - 25 mm
(0 - 1 in)
a - Anti-Ventilation Plate
3. Tighten transom clamp handles.
4. To prevent loss of outboard overboard, fasten outboard by drilling two 7.9 mm (5/16 in.)
holes through the transom using transom clamp holes as a template. Fasten with two
bolts, flat washers and locknuts. Use a marine waterproofing sealer in holes and around
bolts to make the installation water tight.
a
c
a - Bolts (2)
b - Flat washers (2)
c - Locknuts (2)
Steering Cable and Steering Link Rod Installation

Installing Ride Guide Steering Cable to the Outboard
IMPORTANT: Before installing steering cable into tilt tube, lubricate entire cable end
with 2-4-C with Teflon.
1. Lubricate the entire cable end.
95
95 2-4-C with Teflon
90-827242R02 FEBRUARY 2003 Page 1D-3

2. Insert steering cable end through outboard tilt tube and secure steering cable to tilt tube
with steering cable attaching nut as shown. Tighten to specified torque.
b a
53400
a - Cable end
b - Attaching nut
Steering Cable Attaching Nut Torque
47.5 Nm (35 lb-ft)
Steering Cable Seal

1. Place a mark on tilt tube 6.4 mm (.250 in.) from port end of tube. Slide plastic spacer,
O-ring and cap over steering cable end, to tilt tube on engine.
6.4mm
(.250 in.)
e a b c d
53067
a - Mark
b - Spacer
c - O-ring
d - Cap
e - Spacer
2. Thread cap up to the 6.4 mm (1/4 in.) mark.
b
a
53069
a - Cap
b - 6.4 mm (.250 in.) mark
Page 1D-4 90-827242R02 FEBRUARY 2003

Steering Link Rod Installation

IMPORTANT: The steering link rod that connects the steering cable to the engine
must be fastened using special self locking nuts. These locknuts must never be
replaced with common nuts (non-locking) as they will work loose and vibrate off
freeing the link rod to disengage.
WARNING
Disengagement of a steering link rod can result in the boat taking a full, sudden,
sharp turn. This potentially violent action can cause occupants to be thrown
overboard exposing them to serious injury or death.
WARNING
After installation is complete (and before operating outboard), check that boat will
turn right when steering wheel is turned right and that boat will turn left when
steering wheel is turned left. Check steering through full range (left and right) and
at all tilt angles to assure interference-free movement.
1. Secure steering bracket to engine. Tighten nut to specified torque.
d
a
a
53398
a - Steering bracket
b - Bolt (2)
c - Flat washer (2)
d - Locknut (2)
Steering Bracket Nut Torque
15.8 Nm (140 lb-in.)
90-827242R02 FEBRUARY 2003 Page 1D-5

2. Secure steering link rod between engine steering bracket and steering cable end.
95
h
a i
j
95
b
95
c
d
e
f
g
95 2-4-C with Teflon
a - Steering link arm

b - Ball joint (flat end facing up)
c - Steering bracket
d - Spacer - 9.5 mm (3/8 in.)
e - Rubber spacer
f - Flat washer 20.6 mm (13/16 in.)
g - Locknut. Tighten to specified torque.
h - Flat washer [15.9 mm (5/8 in.)] (2)
i - Spacer
j - Locknut. Tighten until nut seats, then back off 1/4-turn
Locknut Torque
27 Nm (20 lb-ft)
Page 1D-6 90-827242R02 FEBRUARY 2003

Remote Control Installation

Refer to Mercury Precision Parts/Quicksilver Accessory Guide for appropriate electric
or manual remote control. Use instructions provided with control for proper installation.
Shift and Throttle Cable Installation to the Outboard

IMPORTANT: Install control cables to remote control and mount control before
attaching control cables to outboard.
Install throttle and shift cables to remote control and mount control as outlined in installation
instructions which accompany the remote control.
NOTE: Attach shift cable to outboard first. Shift cable is the first cable to move when remote
control handle is advanced from NEUTRAL position toward in-gear position.
Refer to the Mercury Precision Parts/Quicksilver Accessory Guide to determine correct
length of remote control cables.
IMPORTANT: Remote control cables must be the correct length. Sharp bends on
too-short cables result in kinks. Too-long cables require unnecessary bends and/or
loops. Both conditions place extra stress on the cables and control.
INSTALLING CABLE RETAINERS ON CABLES
1. Slip cable retainer over the threaded metal end of control cables.
a - Retainer
2. Push cable retainer onto control cables so that the pointed ends are on the top side of
hole.
3. Rotate cable retainer 90° to position end of retainer over hole.
c
a - Retainer
b - Pointed ends
c - Hole
90-827242R02 FEBRUARY 2003 Page 1D-7

4. Install cable ties on control cables.

NOTE: Cable ties will prevent retainers from slipping off cables whenever cables are
removed from engine.
5. Place end of control cables on anchor pins and lock in place with retainers.
b
a - Cable tie
b - Pin
SHIFT CABLE INSTALLATION
1. If remote control has a NEUTRAL lock release, secure the release in the depressed
position using a piece of tape. The true NEUTRAL detent can now be located.
WARNING
To avoid accidental starting which could result in personal injury, remove and
isolate high tension spark leads BEFORE working near propeller.
53258
a - Neutral lock release

b - Tape
Page 1D-8 90-827242R02 FEBRUARY 2003

2. Wrap rubber control cable grommet around shift cable.

a
b
53212
a - Grommet
b - Cable
3. Push grommet with cable into opening in starboard bottom cowl.
53249
a - Grommet
4. Manually shift outboard into neutral position (propeller will rotate freely in both
directions).
5. Adjust barrel on shift cable to attain the same distance between barrel and hole in end
of shift cable as exists between barrel recess of control cable anchor bracket and shift
lever pin.
6. Slip barrel into barrel recess. Place end of shift cable on shift lever pin and lock in place
with cable retainer. Secure barrel after throttle cable is installed.
53253
a - Barrel
b - Pin
c - Retainer
90-827242R02 FEBRUARY 2003 Page 1D-9

7. Check shift cable adjustment as follows:

a. Shift remote control into forward gear. The propeller should not be able to rotate in
a counterclockwise direction. If propeller does rotate counterclockwise, adjust barrel
closer to end of cable and recheck.
b. Shift remote control into neutral. Propeller should turn freely without drag. If not, ad-
just barrel away from end of cable and repeat steps a and b.
c. While rotating propeller shaft, shift remote control into reverse gear. If propeller
can be rotated, adjust barrel away from end of cable and repeat steps a through c.
d. Shift remote control into neutral. Propeller should turn freely without drag. If not, ad-
just barrel closer to end of cable and repeat steps a through d.
THROTTLE CABLE INSTALLATION
NOTE: For easier installation of throttle cable into control cable grommet, apply a soap and
water solution to top and inside of grommet.
1. Install throttle cable into control cable grommet.
2. Move remote control handle forward to wide open throttle position.
3. Slide barrel of throttle cable into barrel recess of control cable anchor bracket. Place end
of cable on throttle lever pin.
4. With remote control in the wide open throttle position, a 1.6 mm (1/16 in.) gap must
exist between guide of anchor bracket and control cable end. Adjust throttle barrel as
required.
5. Secure throttle cable end to throttle lever pin with retainer.
e
c
b h f
d g
a 53254
53252
a - Throttle cable
b - Grommet
c - Barrel
d - Throttle lever pin
e - 1.6mm (1/16 in.) gap
f - Guide
g - Cable end
h - Retainer
Page 1D-10 90-827242R02 FEBRUARY 2003

SPECIAL INSTRUCTIONS
On installations where control cables will frequently be removed and reinstalled after the
initial installation (i.e. inflatable boats), a barrel retaining plug has been supplied as an aid
for installation. Using this plug allows the control cables to installed as a set without further
cable adjustment. Install barrel retaining plug as follows:
1. Without allowing barrels of control cables to rotate, remove cables with cable grommet
from outboard.
2. Install barrel retainer plug between control cable barrels.
3. Wrap cable grommet around control cables.
c
b a
53230 d 53211
a - Barrel retainer plug
b - Control cable barrels
c - Grommet
d - Control cables
4. Push grommet with control cables into opening in starboard bottom cowl.
5. Place remote control in neutral position.
6. Manually shift outboard into neutral position.
7. Slide control cable barrels into barrel recess of anchor bracket.
8. Place ends of control cables onto pins of shift/throttle levers and lock in place with cable
retainers.
b
c
d
e
a
53244 53243
a - Grommet
b - Control cable barrels (2)
c - Shift cable/lever
d - Throttle cable/lever
e - Cable retainers
90-827242R02 FEBRUARY 2003 Page 1D-11

SECURING CABLES TO ANCHOR BRACKET

1. Position barrel retainer over barrels of control cables.
b
a
53254
a - Retainer
b - Barrels
2. Secure barrel retainer with latch. Latch must snap onto barrel retainer.
3. Align hole in latch with hooks of barrel retainer and secure with latch pin.
c b
53251
a - Retainer
b - Latch
c - Pin
Page 1D-12 90-827242R02 FEBRUARY 2003

THROTTLE LINK ROD INSTALLATION

1. Adjust throttle link rod to a length of 21.6 cm (8.5 in.) as measured between ball joint
centerlines.
2. Install throttle link rod between ball joint of throttle control lever and ball joint of actuating
lever.
21.6 cm (8.5 in.)
c
b 53236
a - Throttle link rod [21.6 cm (8.5 in.)]

b - Throttle control lever
c - Actuating lever
Remote Wiring Harness Connection to Engine
1. Apply Dielectric Grease inside the connection.
2. Plug the remote wiring connector into the outboard wiring harness connector. Secure
the connection together with retainer, as shown.
6
b a
6 Dielectric Grease
a - Remote wiring connector

b - Outboard wiring harness connector
c - Retainer
90-827242R02 FEBRUARY 2003 Page 1D-13

Battery Cable Connections

SINGLE OUTBOARD
(+)
(–) c
a - Red sleeve (positive)

b - Black sleeve (negative)
c - Starting battery
DUAL OUTBOARD
1. Connect a common ground cable (wire size same as engine battery cables) between
negative terminals on starting batteries.
(–)
a
(–)
a - Ground cable (same wire size as engine battery cable) - connect between
negative Terminals
Page 1D-14 90-827242R02 FEBRUARY 2003

Tilt Pin Adjustment

Placing Tilt Pin in Lower Holes
1. Lower the bow.

2. Result in quicker planing off, especially with a heavy load or a stern heavy boat.
3. Generally improve the ride in choppy water.
4. Increase steering torque or pull to the right (with the normal right hand rotation
propeller).
5. In excess, lower the bow of some boats to a point at which 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 over-steering if any turn is attempted or if a significant wave is
encountered.
Placing Tilt Pin in Upper Holes
1. Lift the bow out of the water.

2. Generally increase top speed.
3. Increase clearance over submerged objects or a shallow bottom.
4. Increase steering torque or pull to the left at a normal installation height (with the normal
right hand rotation propeller).
5. In excess, cause boat porpoising (bouncing) or propeller ventilation.
90-827242R02 FEBRUARY 2003 Page 1D-15

IGNITION SYSTEM
ELECTRICAL AND IGNITION

Section 2A – Ignition System
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Ignition Troubleshooting (RED Stator) . . . . . . . . 2A-8
2
Special Tools Required . . . . . . . . . . . . . . . . . . . . . 2A-2 Ignition Components Removal and A
Electrical Components . . . . . . . . . . . . . . . . . . . . . 2A-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 Ignition Components Removal and
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10
Ignition Troubleshooting (BLACK Stator) . . . . . 2A-7
Specifications
BLACK Stator
Stator High Speed Winding 120 - 180 Ω (BLACK/WHITE- GROUND)
Stator Low Speed Winding 3000 - 3600 Ω (BLACK/YELLOW -
GROUND)
3100 – 3700 Ω (BLACK/YELLOW -
BLACK/WHITE)
IGNITION Primary 0.02 - 0.04 Ω
SYSTEM Secondary 8000 - 11000 Ω
Readings taken @ Trigger 6500 - 8500 Ω
68°F (20°C).
RED Stator
Stator Capacitor Charging Winding 370 − 445 Ω (GREEN/WHITE - WHITE/
GROUND)
Primary 0.02 - 0.04 Ω
Secondary 8000 - 11000 Ω
Trigger 6500 - 8500 Ω
90-827242R02 FEBRUARY 2003 Page 2A-1

IGNITION SYSTEM
Special Tools Required

1. Flywheel Holder 91-52344
91–52344
54964
2. Flywheel Holder 91-24937A1
3. DMT 2000 Digital Multimeter 91-854009A1
4. Spark Gap Board 91-850439
55117
5. Flywheel Puller 91-83164M
Page 2A-2 90-827242R02 FEBRUARY 2003

IGNITION SYSTEM
Notes:
90-827242R02 FEBRUARY 2003 Page 2A-3

IGNITION SYSTEM
Electrical Components
10
2
1
19
5 2
1
8 15 12
B
5 9 20 13
A 14
11
6
16
7
17
18
30
31 28
29 25
26
32
36 24
33
4 27
34
21
35
22
23
A – RED Stator
B – BLACK Stator
Page 2A-4 90-827242R02 FEBRUARY 2003

IGNITION SYSTEM
Electrical Components (continued)

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 STATOR ASSEMBLY
2 2 SCREW (M5 x 30) 40 4.5
3 1 STATOR AUXILIARY (ELECTRIC/ALTERNATOR MODELS)
4 3 SCREW (M5 x 30) 40 4.5
5 1 SCREW (M5 x 10) (MANUAL) 40 4.5
6 1 TRIGGER ASSEMBLY
7 1 CLIP–trigger lead
8 1 SWITCH BOX
9 3 SCREW–switch box to block (M5 x 35) Drive Tight
10 2 SCREW–ground wire (10-16 x 1/2) Drive Tight
11 2 IGNITION COIL ASSEMBLY
12 2 SCREW–ignition coil 35 3.9
13 2 TAB WASHER
14 2 BUSHING–coil
15 4 NUT–coil terminal 20 2.2
16 1 LEAD ASSEMBLY–high tension
17 2 BOOT ASSEMBLY–spark plug
2 SPARK PLUG (NGK#BP8H-N-10) 6/8
2 SPARK PLUG (NGK#BPZ-8H-N-10)
18
2 SPARK PLUG (NGK#BP8HS-15) 9.9/15
2 SPARK PLUG (NGK#BPZ8HS-15)
AR STA-STRAP (8 IN.)
19
AR STA-STRAP (5-1/2 IN.)
20 1 CABLE–grounding
21 1 HARNESS (62 IN. - BLACK/RED)
22 1 HARNESS (20 IN. - BLACK/RED) SAILPOWER/SAILMATE
23 1 PLUG
24 1 ENGINE WIRING HARNESS
25 1 FUSE
26 1 RETAINER REMOTE CONTROL
27 1 RETAINER
28 1 J-CLAMP
29 1 STARTER MOTOR
30 1 DRIVE KIT
31 1 DRIVE
32 1 END CAP
33 1 ARMATURE
34 1 END CAP
35 2 THRU BOLT
36 2 SCREW (M8 x 55)
90-827242R02 FEBRUARY 2003 Page 2A-5

IGNITION SYSTEM
Description
The ignition system is an alternator driven capacitor discharge system. Major components
of the ignition system are the flywheel, stator, trigger coil, switch box, 2 ignition coils and 2
spark plugs.
The flywheel has permanent magnets mounted in both the outer rim and the center hub.
The BLACK stator assembly is mounted below the flywheel and has a low speed (LS) and
a high speed (HS) capacitor charging coil. Low speed coil provides primary voltage to the
switch box from idle to approximately 2500 RPM. The high speed coil provides primary
voltage from 2000 RPM to the maximum RPM the outboard is capable of achieving.
The RED stator assembly is mounted below the flywheel and has only one capacitor
charging coil.
As the flywheel rotates, the magnets mounted in the flywheel outer rim pass the charging
coils creating voltage. This voltage is rectified to DC and charges the capacitor located in
the switch box.
As the flywheel continues to rotate, the magnets in the center hub pass the trigger coil
creating voltage pulses. These pulses turn on one of the two electronic switches (SCR) in
the switch box. A positive voltage pulse turns on the SCR switch associated with cylinder
#1; a negative voltage pulse turns on the SCR switch associated with cylinder #2.
The SCR switch discharges the stored capacitor voltage into the primary side of the
respective ignition coil. The ignition coil multiplies this voltage to a value high enough to jump
the spark plug gap – 34000 volts for standard coils; 40000 volts for high energy coils.
This sequence occurs once per engine revolution for each cylinder.
Spark timing is changed (advanced/retarded) by rotating the trigger coil on mechanically
advanced models which changes the trigger coil position in relation to the magnets in the
center hub of the flywheel.
Spark timing on electronically advanced models is controlled internally by the switch box
with a fixed trigger.
The stop switch (or ignition switch) shorts the output of the stator to ground to stop the
engine on all models.
Test Procedures
WARNING
When testing or servicing the outboard ignition system, high voltage is present. Be
extremely cautious. DO NOT touch or disconnect any ignition components while
engine is running or while battery cables are connected on electric start models.
It is recommended that the switch box and ignition coils be tested with a Quicksilver
Multi-Meter/DVA, or a voltmeter capable of measuring 400 volts DC or higher, in conjunction
with Quicksilver Direct Voltage Adaptor.
All other components can be tested with an ohmmeter.
Before troubleshooting the ignition system, check the following:
1. On electric models, verify that the electric harness and ignition switch are not the source
of the problem. Check that plug-in connectors are fully engaged and that plug terminals
are free of corrosion.
2. Verify that wire connections are tight and free of corrosion.
3. Inspect all electrical components that are grounded directly to the engine and all ground
wires that they are properly grounded to engine.
4. Inspect for disconnected wires and short and open circuits.
Page 2A-6 90-827242R02 FEBRUARY 2003
IGNITION SYSTEM
Ignition Troubleshooting (BLACK Stator)

TOOL : MULTIMETER/DVA
Multimeter Scale Resistance

Tested Part Connected To
Wires (ohms)
RED BLACK/WHITE
Rx1 120 - 180
BLACK GROUND
Stator (BLACK/
YELLOW and RED BLACK/YELLOW
BLACK/WHITE R x 100 32 - 38
wires disconnected
BLACK GROUND
from switch box)
RED BLACK/YELLOW
R x 100 31 - 37
BLACK BLACK/WHITE
Trigger (BROWN/ RED BROWN/YELLOW

YELLOW and
BROWN/WHITE R x 100 6.5 - 8.5
wires disconnected
from switch box) BLACK BROWN/WHITE
Resistance
Tested Part Multimeter Connected To Scale (ohms)
RED + Terminal
Rx1 0.02 - 0.04
Ignition Coils BLACK – Terminal
(all wires dis- Spark Plug Tower
RED
connected)
R x 1000 8 - 11
BLACK – Terminal
Tested Part Multimeter Connected To Selector Reading At Reading At

Wires Position 300 - 1000 RPM 1000 - 4000 RPM
RED – Terminal
Switch Box
Primary Coil 400 VDC 125 -260 200 - 360
BLACK + Terminal
Switch Box RED GROUND

Stop Circuit
400 VDC 150 - 300 250 - 360
Stator Low
Speed BLACK BLACK/YELLOW
RED GROUND
Stator High
Speed 400 VDC 10 - 75 50 - 300
BLACK BLACK/WHITE
NOTE: Copper is an excellent conductor, but resistance may notably vary between low and
high temperature. Therefore, reasonable differences can be accepted between resistance
readings and specifications.
90-827242R02 FEBRUARY 2003 Page 2A-7
IGNITION SYSTEM
Ignition Troubleshooting (RED Stator)

TOOL : MULTIMETER/DVA
Multimeter Scale Resistance

Tested Part Connected To
Wires (ohms)
Stator (GREEN/
WHITE and RED GREEN/WHITE
WHITE/GREEN Rx1 370 - 445
wires disconnected
BLACK WHITE/GREEN
from switch boxes)
RED BROWN/YELLOW
Trigger (BROWN/
YELLOW and
BROWN/WHITE R x 100 6.5 - 8.5
wires disconnected
from switch boxes) BLACK BROWN/WHITE
Resistance
Tested Part Multimeter Connected To Scale (ohms)
RED + Terminal
Rx1 0.02 - 0.04
Ignition Coils BLACK – Terminal
(all wires dis- Spark Plug Tower
RED
connected)
R x 1000 8 - 11
BLACK – Terminal
Tested Part Multimeter Connected To Selector Reading At Reading At

Wires Position 300 - 1000 RPM 1000 - 4000 RPM
RED – Terminal
Switch Box
Primary Coil 400 VDC 125 - 320 200 - 320
BLACK + Terminal
RED BLACK/YELLOW
Switch Box
Stop Circuit 400 VDC 150 - 330 250 - 330
BLACK GROUND
RED GREEN/WHITE
400 VDC 150 - 330 250 - 330
BLACK GROUND
Stator Voltage
RED WHITE/GREEN
400 VDC 150 - 330 250 - 330
BLACK GROUND
NOTE: Copper is an excellent conductor, but resistance may notably vary between low and
high temperature. Therefore, reasonable differences can be accepted between resistance
readings and specifications.
Page 2A-8 90-827242R02 FEBRUARY 2003
IGNITION SYSTEM
Ignition Components Removal and Installation

CAUTION
Do not strike flywheel with a hard object as flywheel damage could occur. Inspect
flywheel magnets for clinging debris before installation.
WARNING
Engine could possibly start when turning flywheel during removal and installation.
Disconnect (and isolate) spark plug leads.
c 2
a 3
4
Torque Specifications
a 67.8 Nm (50 lb-ft)
5 b 4.5 Nm (40 lb-in.)
c 7.9 Nm (70 lb-in.)
b 6
7
8 b
95
9
95 2-4-C with Teflon 10
53053
1 - Recoil assembly
2 - Bolt (3)
3 - Flywheel nut
4 - Washer
5 - Flywheel
6 - Screw (2)
7 - Stator
8 - Screw (manual)
9 - Trigger
10 - Retainer (trigger)
90-827242R02 FEBRUARY 2003 Page 2A-9

IGNITION SYSTEM
Ignition Components Removal and Installation (continued)

a 4.0 Nm (35 lb-in.) 1 a
b 2.3 Nm (20 lb-in.)
2
c No Torque; Drive Tight
4 b
3
6
25
9 c
10 c
25 Liquid Neoprene
11 53047
1 - Bolt (2)
2 - Retainer (2)
3 - Washer (2)
4 - Nut (4)
5 - Sta-strap (2)
6 - Spark plug lead
7 - Ignition coil
8 - Switch box
9 - Screw (3)
10 - Screw (2)
11 - Terminal block
Page 2A-10 90-827242R02 FEBRUARY 2003

CHARGING AND STARTING SYSTEM

Section 2B – Charging and Starting System
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 Emergency Stop Switch (Lanyard Type) . 2B-17
2
Recommended Battery . . . . . . . . . . . . . . . . . . . 2B-2 Push Button Stop Switch . . . . . . . . . . . . . . 2B-17 B
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Electrical Component Removal and
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18
Operating Engine Without Battery . . . . . . . . . 2B-2 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-19
Battery Charging System Troubleshooting 2B-3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-19
Battery Charging System . . . . . . . . . . . . . . . . . 2B-3 Cleaning and Inspection . . . . . . . . . . . . . . . 2B-20
(1998 And Prior) . . . . . . . . . . . . . . . . . . . . . 2B-3 Testing Motor Armature . . . . . . . . . . . . . . . 2B-20
Alternator Amperes Output 1998 And Prior Starter Motor Reassembly . . . . . . . . . . . . . 2B-21
(Stator - 8 Pole/4 Pulse) . . . . . . . . . . . . . . 2B-4 Starter Solenoid Test . . . . . . . . . . . . . . . . . . 2B-23
Alternator Test (1998 And Prior) . . . . . . . . 2B-4 Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . 2B-24
Rectifier Test (1998 And Prior) . . . . . . . . . 2B-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-24
(1999 And Newer) . . . . . . . . . . . . . . . . . . . . 2B-6 Neutral Start Switch
Alternator Amperes Output 1999 And Newer (Electric Start Tiller Handle Shift Models) . . . 2B-24
(Stator - 10 Pole/5 Pulse) . . . . . . . . . . . . . 2B-6 Tiller Handle Start Button . . . . . . . . . . . . . . . . . 2B-25
Tachometer Module Static Test . . . . . . . . . 2B-7 Choke Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 2B-26
Tachometer Module Running or Cranking Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-26
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9 Battery Cables/Engine Wiring Harness
Rectifier/Regulator (P/N 853358T1) (Remote Electric Start Models) . . . . . . . . . . . . 2B-27
Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 Battery Cables
Digital Meter (DMT 2000 or Equivalent) . 2B-10 (Tiller Handle Push Button Electric Start
Analog Meter . . . . . . . . . . . . . . . . . . . . . . . . 2B-12 Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-29
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-29
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13 Plug Harness (Battery Charging Kit) . . . . . . . 2B-30
Troubleshooting the Starting Circuit . . . . . 2B-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-30
Starting Circuit Troubleshooting Flow Chart . 2B-14 Emergency Stop Switch (Lanyard Type) . . . . 2B-30
COMMANDER 2000 Key Switch Test . . . 2B-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-30
Specifications
STARTING Manual Start Recoil

SYSTEM Electric Start 12 Volt
Starter Draw (Under Load) 55 Amperes
(No Load) 15 Amperes
CHARGING Alternator Output
SYSTEM 2 Magnet Flywheel 4 Amp. (48 Watt)
4 Magnet Flywheel 6 amp (72 Watt)

BATTERY Battery Rating 465 Marine Cranking Amps (MCA)
or 350 Cold Cranking Amps (CCA)
90-827242R02 FEBRUARY 2003 Page 2B-1

Recommended Battery
A 12 volt battery with a Marine Cranking Amperage rating minimum of 465 amperes or a
Cold Cranking Amperage of 400.
Battery
Precautions
When charging batteries, an explosive gas mixture forms in each cell. A portion of this gas
escapes through holes in vent plugs and may form an explosive atmosphere around battery
if ventilation is poor. This explosive gas may remain in or around battery for several hours
after it has been charged. Sparks or flames can ignite this gas and cause an internal
explosion which may shatter the battery.
The following precautions should be observed to prevent an explosion.
1. DO NOT smoke near batteries being charged or which have been charged very recently.
2. DO NOT break live circuits at terminals of batteries because a spark usually occurs at
the point where a live circuit is broken. Always be careful when connecting or
disconnecting cable clamps on chargers. Poor connections are a common cause of
electrical arcs which cause explosions.
3. DO NOT reverse polarity of battery cables on battery terminals.
CAUTION
If battery acid comes into contact with skin or eyes, wash skin immediately with a
mild soap. Flush eyes with water immediately and consult a physician.
Operating Engine Without Battery

In an emergency, engines equipped with an alternator can be started and operated without
a battery, if the WARNING below is followed.
WARNING
Before operating engine with battery leads disconnected from battery, disconnect
stator leads from rectifier and insulate leads from touching ground.
Page 2B-2 90-827242R02 FEBRUARY 2003

Battery Charging System Troubleshooting

A fault in the battery charging system usually will cause the battery to become
undercharged. Check battery electrolyte level, and charge battery. See Electrolyte Level,
and Charging a Discharged Battery.
If battery will NOT accept a satisfactory charge, replace battery.
If battery accepts a satisfactory charge, determine the cause of the charging system
problem as follows.
1. Check for correct battery polarity [RED cable to POSITIVE (+) battery terminal]. If
polarity was incorrect, check for damaged rectifier. Refer to RECTIFIER,
RECTIFIER/REGULATOR TEST.
2. Check for loose or corroded battery connections.
3. Visually inspect wiring between stator and battery for cuts, chafing; and disconnected,
loose or corroded connection.
4. Excessive electrical load (too many accessories) will cause battery to run down.
If visual inspection determines that battery connections and wiring are OK, perform the
following stator and rectifier tests.
Battery Charging System

(1998 And Prior)
The battery charging system components are the alternator, rectifier and battery. Alternating
current flows to the rectifier which changes alternating current (AC) current to direct current
(DC) for charging the battery.
c
b
a - Alternator
b - Rectifier
c - Battery
The charging system may be damaged by:

1. Reversed battery cables.
2. Running the engine with battery cables disconnected and alternator leads connected
to rectifier.
3. An open circuit, such as a broken wire or loose connection.
90-827242R02 FEBRUARY 2003 Page 2B-3

Alternator Amperes Output 1998 And Prior (Stator - 8 Pole/4 Pulse)

Amperage output can be measured by installing a amp meter a (10 amp minimum) in series
between the rectifier and the battery or by clamping an inductive type amp meter (10 amp
minimum) over the RED output lead from the rectifier to the battery.
NOTE: Acceptable alternator amperage output should be within ± 10% of the amperes listed
below.
RPM AMPERES
Idle 0
1000 0
2000 .9
3000 2.5
4000 3.5
5000 4.0
6000 4.3
Alternator Test (1998 And Prior)

NOTE: Alternator can be tested without removing from engine.
1. Disconnect GRAY and YELLOW alternator leads from terminals on either rectifier,
voltage regulator or isolator block.
2. Use an ohmmeter and perform tests as shown in following chart.
3. If meter readings are other than specified, replace alternator assembly.
Test Leads Resistance Scale

RED to YELLOW
0.65* Rx1
BLACK to GRAY
RED to either GRAY or YELLOW
NO CONTINUITY R x 1000
BLACK to GROUND
NOTE: DC resistance of these windings generally is less than 1 ohm. A reading that
resembles a short is acceptable.
Rectifier Test (1998 And Prior)
WARNING
Disconnect battery leads from battery before testing rectifier.
NOTE: Rectifier can be tested without removing from engine.
1. Disconnect all wires from terminals on rectifier.
2. Use an ohmmeter (R x 1000 scale) and perform the following test. Refer to drawing for
rectifier terminal identification.
Page 2B-4 90-827242R02 FEBRUARY 2003

Connect red meter lead to ground (d), black lead

alternately to terminals (a) and (c).
Continuity Indicated No Continuity Indicated

Connect black meter lead to ground (d), red Connect black meter lead to ground (d), red
lead alternately to terminals (a) and (c). lead alternately to terminals (a) and (c).
No Continuity Indicated Continuity Indicated.

Connect black meter lead to terminal (b), red Replace Rectifier.
lead alternately to terminals (a) and (c).
No Continuity Indicated. Continuity Indicated

Replace Rectifier. Connect black meter lead to terminal (b), red
lead alternately to terminals (a) and (c).
Continuity Indicated No Continuity Indicated.

Connect red meter lead to terminal (b), Replace Rectifier.
black lead alternately to terminals (a)
and (c).
Continuity Indicated. No Continuity Indicated
Replace Rectifier. Connect red meter lead to terminal (b),
black lead alternately to terminals (a)
and (c).
No Continuity Indicated. Continuity Indicated.

Rectifier tests O.K. Replace Rectifier. No Continuity Indicated. Continuity Indicated.
Replace Rectifier. Rectifier Tests O.K.
a c
b
d
07300
90-827242R02 FEBRUARY 2003 Page 2B-5

(1999 And Newer)

The battery charging system components are the alternator, rectifier/regulator and the
battery. Alternating current (generated in the alternator/stator coils) flows to the
rectifier/regulator, which changes the alernating current ot direct current for charging the
battery.
a e
b d
c
59093
a - Alternator
b - Tachometer module
c - Tachometer lead
d - Ground leads
e - Rectifier/Regulator
The charging system may be damaged by:
a. Reversed battery cables.
b. Running the engine with battery cables disconnected and alternator leads
connected to rectifier.
c. An open circuit, such as a broken wire or loose connection.
Alternator Amperes Output 1999 And Newer (Stator - 10 Pole/5 Pulse)
Amperage output can be measured by installing a amp meter (10 amp minimum) in series
between the rectifier and the battery or by clamping an inductive type amp meter (10 amp
minimum) over the RED output lead from the rectifier to the battery.
NOTE: Acceptable alternator amperage output should be within ± 10% of the amperes listed
below.
RPM AMPERES
Idle 0
1000 0.75
2000 3.5
3000 4.5
4000 5.0
5000 5.5
6000 6.0
Test Leads Resistance Scale

RED to YELLOW, BLACK to YELLOW 0.5* Rx1
RED to either YELLOW, BLACK to GROUND NO CONTINUITY R x 1000
*DC resistance of these windings generally is less than 1 ohm. A reading that resembles
a short is acceptable.
Page 2B-6 90-827242R02 FEBRUARY 2003

Tachometer Module Static Test

1. Disconnect GRAY, YELLOW, and YELLOW/BLACK tachometer module leads.
2. Set meter to .
NOTE: uses the batteryvoltage within the meter.
3. Connect the multi-meter black lead to engine ground or BLACK harness wire. Connect
the REDmulti-meter lead to the GRAY tachometer module engine bullet connector.
4. Measure voltage.
91-854009A1 b
a
YEL = Yellow
BLK = Black
GRY = Gray
YEL/BLK = Yellow with Black Stripe
59093
a - Tachometer module
b - Engine ground
METER TEST LEADS METER SCALE READING
RED BLACK
TACHOMETER MODULE LEADS O
Open, OUCH
OUCH, or OL
DIODE
GRAY BLACK OR GROUND
5. Connect the multi-meter RED lead to engine ground or BLACK harness wire. Connect
the BLACK multi-meter lead to the GRAY tachometer module bullet connector.
6. Measure voltage.
METER TEST LEADS METER SCALE READING (V)

RED BLACK
TACHOMETER MODULE LEADS 05-0
0.5 0.9
9VVolts
lt
DIODE
BLACK OR GROUND GRAY
7. Set meter to W.
8. Measure resistance.
METER TEST LEADS METER SCALE READING (W)

RED BLACK
TACHOMETER MODULE LEADS 4-8M
Mega Oh
Ohms
W
90-827242R02 FEBRUARY 2003 Page 2B-7

9. Connect GRAY, YELLOW, and YELLOW/BLACK tachometer module leads to engine

harness.
10. Measure resistance.

RED BLACK
TACHOMETER MODULE LEADS 1-3M
Mega Oh
Ohms
W
11. Connect the multi-meter RED lead to the YELLOW tachometer module wire. Connect
the BLACK multi-meter lead to engine ground or to the BLACK tachometer module bullet
connector.

RED BLACK
TACHOMETER MODULE LEADS 5 5 - 8 k Oh
5.5 Ohms
W
YELLOW BLACK OR GROUND
Page 2B-8 90-827242R02 FEBRUARY 2003

Tachometer Module Running or Cranking Test

OUTPUT VOLTAGE TEST
91-854009A1
d c
91-89045-1
b
e
59093
a - Alternator, stator
b - Voltage regulator/rectifier
c - Tachometer module
d - Engine ground leads
e - Gray tachometer lead
1. Disconnect the GRAY tachometer lead.

2. Set meter to Voltage scale.
3. Connect Direct Voltage Adapter to DMT 2000 multi-meter. Connect the multi-meter RED
lead to the GRAY tachometer module wire. Connect the BLACK multi-meter lead to en-
gine ground or to the BLACK tachometor module bullet connector.
4. Crank or start engine.
5. Measure voltage.
METER TEST LEADS METER SCALE READING

RED BLACK
TACHOMETER MODULE LEAD 9 - 14 V
Volts
lt
V
GRAY BLACK OR GROUND
90-827242R02 FEBRUARY 2003 Page 2B-9

Rectifier/Regulator (P/N 853358T1) Diode Test

WARNING
Disconnect battery leads from battery before testing rectifier.
Digital Meter (DMT 2000 or Equivalent)

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.
BLK = Black
RED = Red
YEL = Yellow
1. Set meter to Ω.
2. Connect BLACK (–) meter lead to regulator case.
3. Connect RED (+) meter lead to BLACK lead.
Resistance Specification
0.0 OHMS

5. Connect RED (+) meter lead to RED lead.
4.28 K OHMS
RESISTANCE TEST - SCR

1. Set meter to Ω.
2. Connect RED (+) meter lead to regulator case.
3. Connect BLACK (–) meter lead to either YELLOW regulator lead. Test.
4. Connect BLACK (–) meter lead to YELLOW/BLACK regulator lead.
Resistance Specification (Both Tests)

900 K OHMS Minimum
Page 2B-10 90-827242R02 FEBRUARY 2003

VOLTAGE SPIKE SUPRESSER

1. Set meter to .
3. Connect BLACK (–) meter lead to RED regulator lead.
Voltage Specification
0.4 - 0.7 VOLTS
VOLTAGE SPIKE SUPRESSER DIODE TEST

1. Set meter to .
2. Connect BLACK (–) meter lead to RED regulator lead.
3. Connect RED (+) meter lead to either YELLOW regulator lead. Test.
4. Connect RED (+) meter lead to the other YELLOW regulator lead.
Diode Test Specification (Both Tests)

0.4 - 0.8 VOLTS
DIODE TEST
1. Set meter to .
2. Connect RED (+) meter lead to RED regulator lead.
3. Connect BLACK (–) meter lead to either YELLOW regulator lead. Test.
4. Connect BLACK (–) meter lead to the other YELLOW regulator lead.
Diode Test Specification (Both Tests)

No Continuity - Ouch - OL or 1
SCR TEST
1. Set meter to .
3. Connect RED (+) meter lead to either YELLOW regulator lead. Test.
4. Connect RED (+) meter lead to other YELLOW regulator lead.
SCR Test Specification (Both Tests)

1.5 Volts - No Continuity - Ouch - OL or 1
90-827242R02 FEBRUARY 2003 Page 2B-11

Analog Meter
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.
BLK = Black
RED = Red
YEL = Yellow
DIODE TEST
1. Set Ohm meter to R X 10 scale.
2. Connect RED(+) meter lead to RED regulator lead.
3. Connect BLACK (–) meter lead to either YELLOW or YELLOW/BLACK regulator lead.
100 - 400 OHMS
DIODE TEST
1. Set Ohm meter to R X 1K scale.
2. Connect Black (–) meter lead to RED regulator lead.
3. Connect RED (+) meter lead to YELLOW regulator lead. Test.
4. Connect RED (+) meter lead to the other YELLOW regulator lead.
Test Specification (Both Tests)

40,000 to 1 OHMS (40 K)
SCR TEST
1. Set Ohm meter to R X 1K scale.
3. Connect BLACK (–) meter lead to the YELLOW regulator lead. Test.
4. Connect BLACK (–) meter lead to the other YELLOW lead.
SCR Test Specification (Both Tests)

10,000 OHMS (10K)
Page 2B-12 90-827242R02 FEBRUARY 2003

Starting System
STARTER MOTOR AMPERES DRAW
STARTER MOTOR NO LOAD NORMAL

PART NO. AMP. DRAW AMP. DRAW
50-90983A1 15 AMPS 55 AMPS
Starter Motor Teeth 10
STARTING SYSTEM COMPONENTS

The starting system consists of the following components.
1. Battery
2. Starter Solenoid
3. Neutral Start Switch
4. Starter Motor
5. Ignition Switch
Description
The function of the starting system is to crank the engine. The battery supplies electrical
energy to crank the starter motor. When the ignition switch is turned to “START” position,
the starter solenoid is activated and completes the starting circuit between the battery and
starter.
The neutral start switch opens the start circuit when the shift control lever is not in neutral.
This prevents accidental starting when engine is in gear.
CAUTION
The starter motor may be damaged if operated continuously. DO NOT operate
continuously for more than 30 seconds. Allow a 2 minute cooling period between
starting attempts.
Troubleshooting the Starting Circuit

Before beginning the starting circuit troubleshooting flow chart, following, check first for the
following conditions:
1. Make sure that battery is fully charged.
2. Check that control lever is in NEUTRAL position.
3. Check terminals for corrosion and loose connections.
4. Check cables and wiring for frayed and worn insulation.
5. Check in-line fuse in RED wire. Refer to wire diagram SECTION 2D.
The following STARTING CIRCUIT TROUBLESHOOTING FLOW CHART is designed as
an aid to troubleshooting the starting circuit. This flow chart will accurately locate any
existing malfunction. Location of TEST POINTS are numbered in diagram below.
IMPORTANT: Remote Control Electric Start Models have a 20 Ampere fuse located
under the cowl next to the starter solenoid. This fuse protects the remote control
harness. If this fuse is open, the starter will be inoperative. The cause of the blown
fuse (a short) should be found and corrected.
90-827242R02 FEBRUARY 2003 Page 2B-13

Starting Circuit Troubleshooting Flow Chart
4
To Rectifier/Regualtor
5
53056
Starting Circuit Troubleshooting Flow Chart
Starter Motor Does Not Turn
SAFETY WARNING: Disconnect BLACK (with YELLOW

sleeve) cable from starter solenoid test point 1 BEFORE
making tests to prevent unexpected engine cranking.
TEST 1
Use an ohmmeter (R x 1 scale) and connect meter leads
between NEGATIVE battery post and common powerhead
ground.
No Continuity Indicated Continuity Indicated

There is an open circuit in the BLACK NEGATIVE battery cable Proceed to TEST 2, on next page.
between the NEGATIVE battery post and the powerhead.
• Check cable for loose or corroded connections.
• Check cable for open.
Page 2B-14 90-827242R02 FEBRUARY 2003

* Battery Voltage
TEST 2
a. Connect voltmeter between common engine ground and Test Point 2.
b. Push start switch.
No voltage reading;
proceed to TEST 3.
TEST 3 12 Volt Reading*

a. Connect voltmeter between common engine ground and Test Point 3. Check BLACK ground wire for poor connection
b. Push Start Switch. or open circuit. Reconnect ground wire to start-
er solenoid; proceed to TEST 7.
Electric Start Tiller Handle Model

No voltage reading; 12 Volt Reading
Neutral start switch on lower engine cowl is open
proceed to TEST 4. Defective starter solenoid. or BLACK or WHITE switch leads are disconnected
or damaged. Proceed to TEST 7.
TEST 4
a. Connect voltmeter between common 12 Volt Reading*
engine ground and Test Point 4. Neutral start switch is open, or YELLOW/RED
No voltage reading; b. Push Start Switch. wire is open between Test Points 4 and 3.
proceed to TEST 5.
TEST 5
Connect voltmeter between common 12 Volt Reading*
No voltage reading; engine ground and Test Point 5. Defective ignition switch.
proceed to TEST 6.
TEST 6
Connect voltmeter between common engine ground and Test Point 6.
No voltage reading; check RED wire between 12 Volt Reading*

battery positive terminal and Test Point 6. Check fuse in RED wire between test points 5 and 6.
Check for open RED wire between test points 5 and 6.
TEST 7
a. Connect voltmeter between common engine ground and Test Point 1.
b. Push Start Switch.
No voltage reading; 12 Volt Reading*

Defective starter
Should hear solenoid click; proceed to TEST 8.
solenoid.
TEST 8
a. Reconnect BLACK (starter motor) cable to starter solenoid Test Point 1.
b. Connect voltmeter between common engine ground and Test Point 7
c. Push Start Switch.
No voltage reading; check BLACK cable 12 Volt Reading*

for poor connection or open circuit. Check BLACK ground cable at starter for
loose or corroded connection, or open circuit.
If cable is O.K., check starter motor.
90-827242R02 FEBRUARY 2003 Page 2B-15

COMMANDER 2000 Key Switch Test

1. Disconnect remote control wiring harness and instrument panel connector.
2. Set ohmmeter on R x 1 scale for the following tests:
KEY CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS:

POSITION BLK BLK/YEL RED YEL/RED PUR YEL/BLK
OFF
RUN
START
CHOKE*
*Key switch must be positioned to “RUN” or “START” and key pushed in to

actuate choke for this test.
3. If meter readings are other than specified in the preceding tests, verify that switch and
not wiring is faulty. If wiring checks ok, replace switch.
Page 2B-16 90-827242R02 FEBRUARY 2003

Emergency Stop Switch (Lanyard Type)

IMPORTANT: Refer to Section 2D-Wiring Diagrams for wiring connections.
1. Disconnect emergency stop switch leads from engine wiring.
2. Use an ohmmeter and perform the following tests.
“RUN”
“OFF” NO CONTINUITY
CONTINUITY (∞)
(1 Ohm or Less)
23421
3. If meter readings are other than specified, replace emergency stop switch.
Push Button Stop Switch
IMPORTANT: Refer to Section 2D-Wiring Diagrams for wiring connections.
1. Disconnect push button stop switch leads from engine wiring.
2. Use an ohmmeter and perform the following tests.
CONTINUITY
(I Ohm or Less)
NO CONTINUITY
(∞)
23421
3. If meter readings are other than specified, replace push button stop switch.
90-827242R02 FEBRUARY 2003 Page 2B-17

Electrical Component Removal and Installation
25
a
Voltage Regulator
25
e
Rectifier
25
c a
b
25
Starter Solenoid
53261
a Tighten Securely
b 70 lb. in. (7.9 N·m)
c 15 lb. in. (1.7 N·m)
d 30 lb. in. (3.4 N·m)
25 Liquid Neoprene
e 25 lb. in. (2.8 N·m)
Page 2B-18 90-827242R02 FEBRUARY 2003

Starter Motor
Disassembly
1. Remove 2 thru-bolts from starter.
2. Lightly tap on end of shaft and lower end cap with rubber mallet. Do not lose brush
springs.
a c d
53235
a - Bolts
b - Lower end cap
c - Washers
d - Bolts
3. Tap on drive end cap to loosen. Remove end cap and armature from starter housing.
4. If removal of parts that are installed on armature is necessary, hold armature with Strap
Wrench and remove locknut from end of shaft and discard.
5. Remove parts from shaft.
b
a
b f
c d e g h i
53228
53081
a - Strap Wrench (91-24937A1)

b - Locknut (discard)
c - Spacer
d - Spring
e - Drive Assembly
f - Drive end cap
g - Armature shaft
h - Helix threads
i - Washer
90-827242R02 FEBRUARY 2003 Page 2B-19

Cleaning and Inspection

1. If brushes are pitted, chipped or worn to less than 4.8mm (3/16 in.), replace brushes.
IMPORTANT: DO NOT clean the starter drive assembly or armature shaft while starter
motor is installed on outboard. The cleaning solution will drain dirt into motor
housing.
2. If the motor drive assembly does not fully engage with flywheel, the drive assembly may
be binding on the helix threads on the armature shaft due to dirt or wear. Locate cause
of binding and correct before reassembling.
3. Clean drive components with cleaning solution and inspect parts for wear.
4. Clean commutator with No. 00 sandpaper. Remove any oil from commutator. If
commutator surface is pitted, rough or worn unevenly, resurface on a lathe.
5. Resurface commutator on a lathe as follows:
a. Use a lathe to turn down the commutator surface. DO NOT turn down the
commutator surface excessively.
b. Clean copper particles from slots between commutator bars.
c. Sand the commutator lightly with No. 00 sandpaper to remove burrs. Thoroughly
clean the armature after resurfacing and sanding.
Testing Motor Armature
TESTING ARMATURE FOR SHORTS
1. Place armature in a growler and switch growler on.
2. Hold hack saw blade over armature core while rotating armature.
3. If saw blade vibrates, armature is shorted. Retest after cleaning between commutator
bars. If saw blade still vibrates, replace armature.
01440
a - Hack saw blade
b - Armature core
c - Commutator
Page 2B-20 90-827242R02 FEBRUARY 2003

TESTING ARMATURE FOR GROUND

1. Use an ohmmeter (R x 100) to check for no continuity between commutator and
armature core or commutator and shaft.
2. If continuity exists, armature is grounded and must be replaced.
c a
01441
a - Commutator
b - Core
c - Shaft
Starter Motor Reassembly

1. Reinstall brush assembly.
53075
a - Brush
b - End cap
c - Fiber washer
d - Metal washer
e - Nut
90-827242R02 FEBRUARY 2003 Page 2B-21

2. Apply a drop of SAE 10W oil to to helix threads on armature shaft. DO NOT over
lubricate.
3. Apply a drop of SAE 10W oil to bushings in drive end cap and lower end cap. DO NOT
over lubricate.
4. Reinstall components on armature shaft. Use a new locknut and tighten securely.
f
a g
c e h
b d i
53080
53228
a - Helix threads
b - Locknut
c - Spacer
d - Spring
e - Drive assembly
f - Drive end cap
g - Armature shaft
h - Helix threads
i - Washer
5. Position armature into starter frame so that commutator end of armature is at end of
starter frame where permanent magnets are recessed 33.3mm (1-5/16 in.). Align marks
as shown.
1-5/16 in.
b
53082
a - Alignment marks
b - Bottom edge of permanent magnets
Page 2B-22 90-827242R02 FEBRUARY 2003

6. Install springs and brushes into brush holders. Spread brushes and hold in place with
a strip of spring steel.
7. Push in on drive end of shaft so that commutator will extend out of starter frame.
8. Install lower end cap onto starter frame.
f
b
d
e
c
a 53083
53213
a - Brushes
b - Spring steel
c - Commutator
d - Alignment mark; must align with slot
e - Slot
f - Lower end cap
Starter Solenoid Test

Test starter solenoid as follows:
1. Disconnect all leads from solenoid terminals.
2. Use an ohmmeter, set to R x 1 scale and connect between solenoid terminals 3 and 4.
3. Connect a 12-volt supply between solenoid terminals 1 and 2. Solenoid should click and
meter should read zero ohms.
4. If meter does not read zero ohms (full continuity), replace solenoid.
44 11
a b
2
33 2
14354
a - Ohmmeter leads
b - 12-volt supply
90-827242R02 FEBRUARY 2003 Page 2B-23

Flywheel Ring Gear

Installation
IMPORTANT: Before installing ring gear on flywheel, inspect gear and flywheel for
paint runs which will prevent ring gear from laying flat against flywheel.
1. Inspect (and remove) any paint runs on ring gear and/or mounting surface on flywheel.
2. Place gear on flywheel with countersink side of mounting holes toward the outside.
3. Apply Loctite 271 to threads of 4 gear mounting screws and secure gear to flywheel.
Torque screws to 11.3 Nm (100 lb. in).
a c
7
7 Loctite 271 b
53240
a - Ring gear
b - Flywheel
c - Screws [Torque to 11.3 Nm (100 lb. in.)]
Neutral Start Switch

(Electric Start Tiller Handle Shift Models)
1. Mount neutral start switch onto control platform with 2 bolts and plate.
2. Torque mounting bolts to 0.6 Nm (5 lb. in.).
c b
53077
a - Neutral start switch

b - Plate
c - Bolts [Torque to 0.6 Nm (5 lb. in.)]
Page 2B-24 90-827242R02 FEBRUARY 2003

3. Route switch harness over block. Secure harness to stator harness with cable-tie.
4. Route harness behind rectifier. Attach BLACK lead to solenoid mount bolt. Attach
BLACK lead with YELLOW sleeve to terminal 1 of starter solenoid.
d a
c
e
b
53076
a - Switch harness
b - BLACK lead
c - BLACK lead with YELLOW sleeve
d - Terminal 1
e - Cable-tie
Tiller Handle Start Button

1. The tiller handle start button assembly is secured to the tiller handle by 2 semi-loops
which snap fit onto the tiller throttle shaft. To remove the button assembly, pry the
assembly away from the tiller handle with a flat tip screwdriver.
2. The starter button harness is routed into the lower cowl through the fuel connector
access hole.
a
d
c
53216
a - Start button assembly

b - Semi-loops
c - Harness
d - Fuel connector
90-827242R02 FEBRUARY 2003 Page 2B-25

3. The starter button harness is routed down the PORT side of lower engine to cowl.
4. The RED harness lead is connected to the POSITIVE terminal of the rectifier. Torque
attaching nut to 2.8 Nm (25 lb. in.).
5. The YELLOW/RED harness lead attaches to the #2 terminal of the starter terminal.
Torque attaching nut to 1.7 Nm (15 lb. in.).
b a
53215
a - RED Lead [Torque nut to 2.8 Nm (25 lb. in.)]

b - YELLOW/RED Lead [Torque nut to 1.7 Nm (15 lb. in.)]
Choke Solenoid
Installation
IMPORTANT: New gasket MUST be positioned as shown when being installed.
1. Install new gasket with solenoid plate assembly.
2. Secure assembly with 2 screws. Torque screws to 2.0 Nm (18 lb. in.).
a
c
b
53209
a - Gasket
b - Solenoid plate
c - Screws [Torque to 2.0 Nm (18 lb. in.)]
Page 2B-26 90-827242R02 FEBRUARY 2003

Battery Cables/Engine Wiring Harness

(Remote Electric Start Models)
1. Slide battery cables through sleeve.
2. Thread battery cable/sleeve through wire retainer of engine wiring harness. Verify
25.4mm (1 in.) of sleeve remains to the outside of wire retainer.
25.4mm (1 in.)
c
d
e
53066 53065
a - Battery cables
b - Sleeve
c - Sleeve
d - Retainer
e - Harness
3. Remove carburetor as outlined in Section 3.

4. Thread engine wiring harness first and then battery cable/sleeve through opening in
bottom cowl.
53210
a - Harness
b - Battery cable/sleeve
c - Opening
90-827242R02 FEBRUARY 2003 Page 2B-27

5. Route engine wiring harness and battery cable/sleeve (under carburetor location)
around to PORT side of cylinder block.
6. Push wire retainer into opening of bottom cowl and secure with clip.
53068
a - Clip
7. Secure harness and battery cable/sleeve with cable-tie just inside bottom cowl.
8. Reinstall carburetor. Refer to Section 3A.
9. Secure fuse holder in J-clip.
a c
b
53226
a - Cable-tie
b - Fuse holder
c - J-clip
10. Plug remote control harness connector into engine wiring harness connector and
secure with harness connector retainer.
b a
c 53064
a - Remote control harness

b - Engine harness
c - Retainer
Page 2B-28 90-827242R02 FEBRUARY 2003

Battery Cables
(Tiller Handle Push Button Electric Start Models)
Installation
1. Fasten harness clamp to bottom cowl with nut, washer and bolt.
b a
c
d
53069
a - Clamp
b - Nut
c - Washer
d - Bolt
2. Slide battery cables through sleeve.

3. Slide harness clamp over battery cable sleeve and position cables into bottom cowl.
4. Position harness clamp onto clamp bracket in bottom cowl. Tighten clamp securely.
5. Slide battery cable grommet over battery cables and install grommet into opening in
starboard bottom cowl.
b
a d
53149
53067
a - Clamp
b - Bracket
c - Grommet
d - Cables
90-827242R02 FEBRUARY 2003 Page 2B-29

Plug Harness (Battery Charging Kit)

Installation
1. Install plug harness through fuel fitting opening in bottom cowl.
2. Route harness along PORT side of engine to rectifier.
a
53063
a - Harness
3. Refer to Section 2D for wiring connections.
Emergency Stop Switch (Lanyard Type)

Installation
1. Route emergency stop switch wiring through opening in STARBOARD bottom cowl.
2. Secure stop switch into opening in bottom cowl using clip.
a
53054
53055
a - Stop Switch
b - Clip
3. Refer to Section 2D for wiring connections.
Page 2B-30 90-827242R02 FEBRUARY 2003

TIMING, SYNCHRONIZING & ADJUSTING

Section 2C – Timing, Synchronizing & Adjusting
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Tiller Handle Shift Models . . . . . . . . . . . . . . . 2C-3
2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Maximum Timing Adjustment . . . . . . . . . . . . 2C-4 C
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Idle Timing Adjustment . . . . . . . . . . . . . . . . . . 2C-4
Side Shift Models . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Fast Idle Adjustment . . . . . . . . . . . . . . . . . . . . 2C-5
Specifications
MAXIMUM TIMING 36° BTDC
IDLE TIMING
6/8/9.9/10/15 8° BTDC ± 1°
IDLE RPM IN FORWARD GEAR –
650 ± 75
6 725 ± 50
8/9.9/15 850 ± 50
10 SEA PRO 850 ± 50
MARATHON 725 ± 50
XR/MAG/VIKING 10
15 SEA PRO 725 ± 50
MARATHON
FULL THROTTLE RPM
6 4000 – 5000
8 4500 – 5500
9.9/10/15 5000 – 6000
SPARK PLUG (1994)
6/8/9.9 NGK BP8H-N-10
10/15 NGK BP8HS-15
SPARK PLUG GAP
6/8/9.9 1.0mm (0.040 in.)
10/15 1.5mm (0.060 in.)
SPARK PLUG (1995 AND NEW-
ER) NGK BP8H-N-10
6/8 NGK BP8HS-15
9.9/10/15
SPARK PLUG GAP 1.0mm (0.040 in.)
6/8 1.5mm (0.060 in.)
9.9/10/15
NEUTRAL FAST IDLE 1500 – 2000 RPM
90-827242R02 FEBRUARY 2003 Page 2C-1

Special Tools
1. DMT 2000 Service Tachometer 91-854009A1
2. Timing Light 91-99379
Adjustments
1. Place engine in water.
Side Shift Models
1. Check tiller handle cable adjustment for full throttle movement in both Forward and
Reverse gears.
2. Adjust jam nuts for proper travel and to eliminate any slack.
a - Jam nuts
Page 2C-2 90-827242R02 FEBRUARY 2003

Tiller Handle Shift Models

1. Rotate tiller handle twist grip to NEUTRAL.
2. Adjust jam nuts to remove slack from control cables while allowing full travel of throttle/
shift linkage.
53046
a
a - Jam nuts
TIMING POINTER LOCATION
40 30 20 10
a
a - Timing pointer
90-827242R02 FEBRUARY 2003 Page 2C-3

Maximum Timing Adjustment

1. Connect timing light to No. 1 (top) spark plug lead.
2. With engine in Forward gear, fully advance throttle to WOT (Wide Open Throttle)
position.
3. Adjust maximum spark advance screw to align the 36° BTDC (Before Top Dead Center)
timing mark on flywheel with timing pointer. Tighten jam nut if so equipped.
4. Adjust low speed mixture screw. Refer to Section 3A-Carburetor Adjustments.
a - Maximum spark advance screw

b - Jam nut
Idle Timing Adjustment

1. Push primer/fast idle knob completely in and rotate knob fully counterclockwise.
2. With engine running in Forward gear, reduce engine speed to idle.
IMPORTANT: It may be necessary to adjust idle speed screw to obtain a reasonably
stabilized idle.
3. Adjust idle timing adjustment screw to align the specified idle timing mark on flywheel
with timing pointer.
4. Shift to Neutral gear and stop engine.
a - Idle timing adjustment screw
Page 2C-4 90-827242R02 FEBRUARY 2003

Fast Idle Adjustment

1. Push primer/fast idle knob completely in and rotate knob fully COUNTERCLOCKWISE.
2. Shift outboard to NEUTRAL.
3. Adjust screw to remove all clearance between idle wire and trigger.
b
a
23970
a - Fast idle screw
b - Idle wire
4. Check fast idle by turning primer knob to full CLOCKWISE position. Fast idle speed
should be 1500 – 2000 RPM.
90-827242R02 FEBRUARY 2003 Page 2C-5

WIRING DIAGRAMS

Section 2D – Wiring Diagrams
Table of Contents
Manual Start Ignition Wiring Diagram Electric Models Equipped with Remote Control
2
(1998 And Prior) . . . . . . . . . . . . . . . . . . . . . . . . 2D-2 (1999 And Newer, Design I) . . . . . . . . . . . . . . 2D-8 D
Electric Start Models with Tiller Handle Start Electric Start Models with Tiller Handle Start
Button (1998 And Prior) . . . . . . . . . . . . . . . . . 2D-3 Button (1999 And Newer, Design II) . . . . . . . 2D-9
Electric Models Equipped with Remote Control Electric Models Equipped with Remote Control
(1998 And Prior) . . . . . . . . . . . . . . . . . . . . . . . . 2D-4 (1999 And Newer, Design II) . . . . . . . . . . . . . 2D-10
Manual Start Ignition Wiring Diagram Optional Electrical Accessories Wiring
(1999 And Newer) . . . . . . . . . . . . . . . . . . . . . . . 2D-5 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-11
Manual Start Ignition Wiring Diagram Commander 2000 Remote Control (Manual) 2D-12
(1999 And Newer) (Marathon and Commander 2000 Remote Control (Electric
Sea Pro Models) . . . . . . . . . . . . . . . . . . . . . . . . 2D-6 Start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-13
Electric Start Models with Tiller Handle Start Commander 3000 Panel Mount Control . . . . 2D-14
Button (1999 And Newer, Design I) . . . . . . . 2D-7
90-827242R02 FEBRUARY 2003 Page 2D-1

WIRING DIAGRAMS
Manual Start Ignition Wiring Diagram (1998 And Prior)

aa d
cc
ff ee
BLK = BLACK
BRN = BROWN
GRY = GRAY
GRN = GREEN
RED = RED
WHT = WHITE
YEL = YELLOW
a - Stator
b - Trigger
c - Switch box
d - Ignition coil top cylinder
e - Ignition coil bottom cylinder
f - Stop switch
g - Emergency stop switch
Page 2D-2 90-827242R02 FEBRUARY 2003

WIRING DIAGRAMS
Electric Start Models with Tiller Handle Start Button

(1998 And Prior)
f
h
dd
jj
bb
cc
ii
kk
ee
BLK = Black
ll BRN = Brown
m
m
GRY = Gray
GRN = Green
RED = Red
WHT = White
YEL = Yellow
a - Stator
b - Trigger
c - Switch box
f - Alternator stator
g - Rectifier
h - Starter motor
i - Starter solenoid
j - Neutral start switch
k - Start switch
l - Stop switch
m - Emergency stop switch
90-827242R02 FEBRUARY 2003 Page 2D-3

WIRING DIAGRAMS
Electric Models Equipped with Remote Control

(1998 And Prior)
f
hh
k
a dd
bb
j i cc
g
ee
l
BLK = BLACK
BRN = BROWN
GRY = GRAY
GRN = GREEN
RED = RED
WHT = WHITE
YEL = YELLOW
a - Stator
b - Trigger
c - Switch box
f - Alternator stator
g - Rectifier
h - Starter motor
i - Starter solenoid
j - Fuse holder (20 ampere fuse)
k - Choke solenoid
l - Wiring harness
Page 2D-4 90-827242R02 FEBRUARY 2003

WIRING DIAGRAMS
Manual Start Ignition Wiring Diagram (1999 And Newer)

aa
BLK BLK
Z1
bb dd
cc
#2
GRN
Z1
BLK
BLK
Z1
GRN/WHT
ee
WHT/GRN
BRN/YEL
BRN/WHT
#1
GRN/YEL
Z1
J1
J4
J2
J3
Z1
Z1
Z1
Z1
BRN/YEL
BRN/WHT
GRN/WHT
WHT/GRN
BLK/YEL Z1 J5
BLK/YEL
g BLK/YEL J7 J6 BLK/YEL
BLK BLK ff
T4
T5
BLK = BLACK
BRN = BROWN
GRY = GRAY
GRN = GREEN
RED = RED
WHT = WHITE
YEL = YELLOW
a - Stator
b - Trigger
c - Switch box
d - Ignition coil bottom cylinder
e - Ignition coil top cylinder
f - Emergency stop switch
g - Stop switch
90-827242R02 FEBRUARY 2003 Page 2D-5

WIRING DIAGRAMS
Manual Start Ignition Wiring Diagram (1999 And Newer)

(Marathon and Sea Pro Models)
aa
BLK BLK
b cc dd
#2
GRN
BLK
BLK
BRN/WHT e
BRN/YEL
GRN/WHT
WHT/GRN
#1
GRN/YEL
GRY
YEL
J1
J4
J2
J3
hh
Z1
Z1
Z1
Z1
BRN/YEL
BRN/WHT
GRN/WHT
WHT/GRN
BLK/YEL Z1 J5
BLK/YEL
gg BLK/YEL J7 J6
BLK/YEL
BLK
BLK
f
BLK = BLACK
BRN = BROWN
GRY = GRAY
GRN = GREEN
RED = RED
WHT = WHITE
YEL = YELLOW
a - Stator
b - Trigger
c - Switch box
f - Stop switch
g - Emergency stop switch
h - Alternator stator
Page 2D-6 90-827242R02 FEBRUARY 2003

WIRING DIAGRAMS

(1999 And Newer, Design I)
n
n aa
BLK BLK
b
b c dd
#2
GRN
BLK
BLK
ee
Z1 J1 GRN/WHT
Z1 J2 WHT/GRN
BRN/WHT Z1 J4 BRN/WHT
BRN/YEL Z1 J3 BRN/YEL
#1
GRN/YEL
l
GRY
YEL
ii
jj
WHT/GRN
GRN/WHT
YEL
BLK
YEL/RED
RED
h BLK/YEL Z1 J5
BLK
BLK
RED
RED
BLK/YEL
BLK
g
g BLK/YEL
BLK
J7 J6
BLK/YEL
f
BLK
BLK
– +
YEL/RED
RED k BLK = BLACK
BRN = BROWN
GRY = GRAY
m
m GRN = GREEN
RED = RED
WHT = WHITE
YEL = YELLOW
a - Stator
b - Trigger
c - Switch cox
g - Push button stop switch
h - Rectifier
i - Alternator stator
k - Push button start switch
l - Start solenoid
m - 12 VDC battery
n - Starter motor
90-827242R02 FEBRUARY 2003 Page 2D-7

WIRING DIAGRAMS
Electric Models Equipped with Remote Control (1999 And

Newer, Design I)
m a
BLK BLK
b c
dd
#2
GRN
BLK
BLK
ee
GRN/WHT Z1 J1 GRN/WHT
WHT/GRN Z1 J2 WHT/GRN
#1
GRY GRN/YEL
YEL
BLK jj
BLK
J7 J6 YEL/BLK
f
BLK
BLK
YEL
GRY
BLK
YEL/RED
i
RED
kk h BLK/YEL Z1 J5 BLK/YEL 1
RED
2
BLK 3
BLK
GRY
4
5 g
YEL/BLK 6
– + YEL/RED 7
RED 8
l BLK = BLACK
BRN = BROWN
GRY = GRAY
GRN = GREEN
RED = RED
WHT = WHITE
YEL = YELLOW
a - Stator
b - Trigger
c - Switch box
f - Choke solenoid
g - Remote control harness
h - Fuse holder (20 ampere fuse)
i - Rectifier
j - Alternator stator
k - Starter solenoid
l - 12 VDC battery
m - Starter motor
Page 2D-8 90-827242R02 FEBRUARY 2003

WIRING DIAGRAMS

(1999 And Newer, Design II)
n a
b
BLK BLK
c d
#2
GRN
BLK
BLK
Z1 J1 GRN/WHT
Z1 J2 WHT/GRN
#1
GRN/YEL
l YEL
YEL
i
j
WHT/GRN
GRN/WHT
YEL
BLK
YEL/RED
BLK/YEL Z1 J5
f
BLK
BLK
RED
RED
BLK/YEL
BLK/YEL J7 J6
BLK g BLK
BLK/YEL
BLK
BLK
– +
J1 Z1
YEL J1 Z1
YEL J1 Z1
J1
YEL/BLK
k
RED
GRY
m BLK = BLACK
o
YEL
BRN = BROWN
BLK
GRY = GRAY
h GRN = GREEN
RED = RED
WHT = WHITE
YEL = YELLOW
a - Stator
b - Trigger
c - Switch box
g - Push button stop switch
h - Rectifier/Regulator
i - Alternator stator
k - Push button start switch
l - Start solenoid
m - 12 VDC battery
n - Starter motor
o - Tachometer module
90-827242R02 FEBRUARY 2003 Page 2D-9

WIRING DIAGRAMS
Electric Models Equipped with Remote Control (1999 And

Newer, Design II)
m a
b
BLK BLK
c d
#2
GRN
BLK
BLK
GRN/WHT Z1 J1 GRN/WHT
WHT/GRN Z1 J2 WHT/GRN
#1
GRN/YEL
YEL
YEL
BLK j
BLK
J7 J6 YEL/BLK
f
BLK
BLK
YEL
BLK
YEL/RED
Z1 J5
Z1 J5
k BLK/YEL Z1 J5 BLK/YEL 1
RED
2
BLK 3
BLK
GRY
4
5
g
YEL/BLK 6
– + YEL/RED 7
RED 8
h
Z1
l BLK = BLACK
J1 Z1
YEL J1 Z1
YEL J1 Z1
J1
YEL/BLK
BRN = BROWN
GRY = GRAY
RED
GRY
GRN = GREEN
n
YEL
RED = RED
BLK
WHT = WHITE
YEL = YELLOW
i
a - Stator
b - Trigger
c - Switch box
e - Ignition coil top cylider
f - Choke solenoid
g - Remote control harness
h - Fuse holder (20 ampere fuse)
i - Rectifier/Regualator
j - Alternator stator
k - Starter solenoid
l - 12 VDC battery
m - Starter motor
n - Tachometer module
Page 2D-10 90-827242R02 FEBRUARY 2003

WIRING DIAGRAMS
Optional Electrical Accessories Wiring Diagrams
Rectifier
Terminal
Block
Manual Start Model with Lighting Coil Manual Start Model with Battery
and Unregulated AC Voltage Charging Kit
Late Model
Voltage
Regulator
Tachometer
Module
Early Model
Voltage
Regulator
Late Model Voltage Regulator with

Manual Start Model with Tachometer Module
Voltage Regulator
90-827242R02 FEBRUARY 2003 Page 2D-11

WIRING DIAGRAMS
Commander 2000 Remote Control (Manual)
BLK=BLACK
YEL=YELLOW
aa
23893
a - RUN – OFF switch

b - Emergency stop switch
c - Stop switch harness
Page 2D-12 90-827242R02 FEBRUARY 2003

WIRING DIAGRAMS
Commander 2000 Remote Control (Electric Start)

BLK = BLACK
BRN = BROWN
GRY = GRAY
GRN = GREEN
RED = RED
WHT = WHITE
YEL = YELLOW
d
b
ee
23890
a - Ignition/Choke switch
c - Neutral start switch
d - Tachometer/Accessories harness connector
e - Wiring harness connector
90-827242R02 FEBRUARY 2003 Page 2D-13

WIRING DIAGRAMS
Commander 3000 Panel Mount Control
Neutral Interlock
Switch
RED=RED
YEL=YELLOW
a - Neutral interlock switch

Page 2D-14 90-827242R02 FEBRUARY 2003

FUEL DELIVERY SYSTEM
FUEL SYSTEM
Section 3A – Fuel Delivery System
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2 Fuel System Troubleshooting . . . . . . . . . . . . . 3A-12
WMC Carburetor Specifications . . . . . . . . . . . 3A-3 General Information . . . . . . . . . . . . . . . . . . 3A-12
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-5 Carburetor Removal . . . . . . . . . . . . . . . . . . . . . 3A-14
Carburetor Assembly (6 - 8)
(9.9 - USA–S/N-0G112449/BEL
Carburetor Installation . . . . . . . . . . . . . . . . . . .
Carburetor Adjustments . . . . . . . . . . . . . . .
3A-15
3A-17 3
–S/N-9831799 & Below) . . . . . . . . . . . . . . . . . .
Carburetor Assembly (15) USA
3A-6 Rejetting Carburetors for High Altitude . .
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3A-22
3A-23
A
–S/N-0G112449/BEL–S/N-9831799 & Below 3A-8 Removal and Disassembly . . . . . . . . . . . . 3A-23
CARBURETOR ASSEMBLY USA Cleaning and Inspection . . . . . . . . . . . . . . . 3A-23
–S/N-0G112450 BEL–S/N-9831800 & Up . . 3A-10 Reassembly and Installation . . . . . . . . . . . 3A-23
Carburetor Assembly USA–S/N-0G112450/BEL Primer System . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-24
–S/N-9831800 & Up . . . . . . . . . . . . . . . . . . . . . 3A-11 Servicing Sight Bowl Fuel Filter . . . . . . . . . . . 3A-25
90-827242R02 FEBRUARY 2003 Page 3A-1

Specifications
Models 6/8/9.9/10/15
Type Center Bowl, Integral Fuel Pump
Idle RPM (In Gear) –
6 650 ± 75
8 725 ± 50
9.9/9.9 Sailpower 725 ± 50
10 Sea Pro/Marathon 850 ± 50
XR/MAG/Viking10 725 ± 50
15 725 ± 50
Wide Open Throttle RPM
6 4000 – 5000
8 4500 – 5500
9.9/9.9 Sailpower 5000 – 6000
XR/MAG/Viking10 5000 – 6000
15 5000 – 6000
Idle Mixture Screw (Initial Setting) 5000 – 6000
CARBURETOR Float Setting (All Models) Refer to Section 3A
SPECIFICATIONS Main Jet – 1 in. (25.4mm)
Thread size
10–32
1994 Model Year
6 .042
8 .046
XR10/MAG10 .052
15 .066
1995 and Newer
6 .042
8 .046
XR10/MAG10 052
15/Viking10 .072
Page 3A-2 90827242R02 FEBRUARY 2003

WMC Carburetor Specifications

1994
MAIN JET
0 – 5000 ft 5000 – 7500 ft 7500 – 10000 ft FLOAT IDLE
MODEL CARB
(0 – 1524m) (1524 – 2286m) (1524 – 3048m) LEVEL MIX
25.4mm
6 WMC-20B .042 .040 .038
(1 in.) 1-3/8 ± 1/4
25.4mm
8 WMC-18B .046 .044 .042 1-3/8 ± 1/4
(1 in.)
25.4mm
9.9 WMC-23 .052 .050 .048 1-3/8 ± 1/4
(1 in.)
XR10 25.4mm
WMC-23 .052 .050 .048 1-3/8 ± 1/4
Mag 10 (1 in.)
Seapro
Marathon WMC-42 25.4mm
.064 .062 .060 1-3/8 ± 1/4
10 (1 in.)
15 WMC-73 .064 .062 .060 25.4mm 1-3/8 ± 1/4

(1 in.)
1995 - 1996
MAIN JET
MODEL CARB
(0 – 1524m) (1524 – 2286m) (1524 – 3048m) LEVEL MIX
25.4mm
6 WMC-20B .042 .040 .038 1-3/8 ± 1/4
(1 in.)
25.4mm
8 WMC-41 .046 .044 .042 1-1/2 ± 1/4
(1 in.)
25.4mm
9.9 WMC-47 .048 .046 .044 1-1/2 ± 1/4
(1 in.)
XR10 WMC-48 .052 .050 .048

25.4mm 1-1/2 ± 1/4
Mag 10 (1 in.)
Seapro WMC-50
25.4mm 1-1/2 ± 1/4
Marathon .052 .050 .048
(1 in.)
WMC-50A
10
25.4mm
15 WMC-49 .072 .068 .066 1-1/2 ± 1/4
(1 in.)
90-827242R02 FEBRUARY 2003 Page 3A-3


1997
MAIN JET
MODEL CARB
(0 – 1524m) (1524 – 2286m) (1524 – 3048m) LEVEL MIX
25.4mm
6 WMC-20B .042 .040 .038 1-3/8 ± 1/4
(1 in.)
8 WMC-41 .046 .042 25.4mm 1-1/2 ± 1/4

.044
(1 in.)
25.4mm 1-1/2 ± 1/4

9.9 WMC-47 .048 .046 .044
(1 in.)
XR10 25.4mm
WMC-48 .052 .050 .048 1-1/2 ± 1/4
Mag 10 (1 in.)
Seapro
Marathon WMC-50A .052 .048 25.4mm 1-1/2 ± 1/4
.050
(1 in.)
10
25.4mm
15 WMC-49 .072 .068 .066
(1 in.) 1-1/2 ± 1/4
15 25.4mm
Seapro WMC-55 .072 .068 .066 1-1/2 ± 1/4
(1 in.)
Marathon
1998 – 2001
MAIN JET
MODEL CARB
(0 – 1524m) (1524 – 2286m) (1524 – 3048m) LEVEL MIX
25.4mm
6 WMC-57 .042 .040 .038 (1 in.) 1-1/4 ± 1/4
25.4mm
8 WMC-41A .046 .044 .042 1-1/2 ± 1/4
(1 in.)
25.4mm
9.9 WMC-47A .048 .046 .044 1-1/2 ± 1/4
(1 in.)
XR10 WMC-48A .052 .050 .048 25.4mm 1-1/2 ± 1/4

Mag 10 (1 in.)
Seapro
Marathon WMC-50B .052 .050 .048 25.4mm 1-1/2 ± 1/4
10 (1 in.)
25.4mm
15 WMC-49A .072 .068 .066 1-1/2 ± 1/4
(1 in.)
15 25.4mm
Seapro WMC-55A .072 .068 .066
(1 in.) 1-1/2 ± 1/4
Marathon

2002 and UP
MAIN JET
MODEL CARB
(0 – 1524m) (1524 – 2286m) (1524 – 3048m) LEVEL MIX
25.4mm
6 WMC-66 .042 .040 .038 (1 in.) 1-1/4 ± 1/4
25.4mm
8 WMC-74 .046 .044 .042 1-1/2 ± 1/4
(1 in.)
25.4mm
9.9 WMC-61 .048 .046 .044 1-1/2 ± 1/4
(1 in.)
XR10 25.4mm
Mag 10 WMC-62 .052 .050 .048 1-1/2 ± 1/4
(1 in.)
Seapro 25.4mm
Marathon WMC-50B .052 .050 .048 1-1/2 ± 1/4
(1 in.)
10
10 25.4mm
WMC-63 .072 .068 .066 1-1/2 ± 1/4
Viking (1 in.)
15 25.4mm
WMC-77 .072 .068 .066 (1 in.) 1-1/2 ± 1/4
15
Seapro .072 .068
25.4mm
1-1/2 ± 1/4
.066
Marathon WMC-55A (1 in.)
Special Tools
1. Carburetor Scale
90-827242R02 FEBRUARY 2003 Page 3A-5

(9.9 - USA–S/N-0G112449/BEL–S/N-9831799 & Below)
17
15
16 39
20 2 22
22 43
43 23
43
43 43 1
43
3 31
25
37
29
43 28 30
8 12
36 6 40
7
22 11
22 27 41
13 5 43
43 24
21 32
22
22 22 43 26
18 43 33
34
14 43
4 35
38
9 43
10
19
22
42

(9.9 - USA–S/N-0G112449/BEL–S/N-9831799 & Below) (continued)
TORQUE
REF.
REF
1 1 CARBURETOR
2 1 THROTTLE VALVE
3 1 SHAFT
4 1 FUEL BOWL
5 1 FLOAT
6 1 FLOAT PIN
7 1 SCREW
8 1 INLET NEEDLE VALVE
9 1 MAIN FUEL JET
10 1 PLUG–jet retainer 33 3.7
11 1 COVER–diaphragm
12 4 SCREW 14 1.6
13 1 FUEL PUMP KIT
14 5 SCREW–fuel pump 18 2.1
15 1 PLATE
16 1 GASKET–electric choke
17 2 SCREW 18 2.1
18 1 COVER–fuel pump
19 1 PLUG 33 3.7
20 1 GASKET–carburetor (Use where applicable)
21 1 DIAPHRAGM
22 1 GASKET/DIAPHRAGM KIT
23 1 IDLE WIRE
24 1 FAST IDLE LEVER
25 1 PRIMER BRACKET
26 1 PUSHNUT
27 1 SCREW
28 1 SPRING
29 2 SCREW (M5 x 8 x 12) 33 3.7
30 1 SCREW Tighten Securely
31 1 PRIMER LEVER
32 1 CAM BLOCK
33 1 RETAINING CLIP
34 1 CHOKE BEZEL
35 1 PRIMER KNOB
36 1 SCREW
37 1 NUT
38 1 DECAL (SLOW/FAST)
39 1 ELECTRIC CHOKE
40 1 COVER
41 1 PLUG
42 1 RESTRICTOR KIT
43 1 REPAIR PARTS KIT
90-827242R02 FEBRUARY 2003 Page 3A-7

Carburetor Assembly (15)

USA–S/N-0G112449/BEL–S/N-9831799 & Below
14 37
13
15
15 2 16
16
19 36
16
16 16 1
3 28
22
34 26
6 27
25
16 10
33 16 35
16
15 9
16 15 24
11 5 16
16 21 29
15 15
16 15 23 30
17 20 16 16
12 31
16
4 32
16
7
8 18
15
16
38
39

Carburetor Assembly (15)

USA–S/N-0G112449/BEL–S/N-9831799 & Below (continued)
TORQUE
REF.
REF
1 1 CARBURETOR (WMC-73)
2 1 THROTTLE VALVE
3 1 THROTTLE SHAFT (INCLS. SCREW & SPRING)
4 1 FUEL BOWL
5 1 FLOAT
7 1 MAIN FUEL JET (.066)
10 4 SCREW–diaphragm cover 14 1.7
11 1 FUEL PUMP KIT
12 5 SCREW–fuel pump cover 18 2.1
13 1 PLATE–cover
14 2 SCREW–cover plate 18 2.1
17 1 COVER–fuel pump
18 1 PLUG 33 3.7
19 1 GASKET–carburetor
20 1 DIAPHRAGM
22 1 PRIMER BRACKET
23 1 PUSHNUT
24 1 SCREW
25 1 SPRING
26 2 SCREW (M5 x 8 x 12) 33 3.7
27 1 SCREW Tighten Securely
28 1 PRIMER LEVER
29 1 CAM BLOCK
30 1 RETAINING CLIP
31 1 CHOKE BEZEL
32 1 PRIMER KNOB
33 1 SCREW
34 1 NUT
35 1 DECAL (SLOW/FAST)
36 1 IDLE WIRE
37 1 ELECTRIC CHOKE
38 1 COVER
39 1 PLUG
90-827242R02 FEBRUARY 2003 Page 3A-9

CARBURETOR ASSEMBLY
USA–S/N-0G112450/BEL–S/N-9831800 & Up
17 40
15
16
20 2 22
22 23
23
24
23
23 23 1
3 23
26 32
38
30
29 31
8 12
37 7 6
22 23 23 11
23 22 28
13 5 23
23 25
21 33
22
22 22 23 27 34
18 23
14 23 35
4 36
39
9 23
10
19
22
23
41
Page 3A-10 90827242R02 FEBRUARY 2003

Carburetor Assembly
USA–S/N-0G112450/BEL–S/N-9831800 & Up (continued)
TORQUE
REF.
REF
1 1 CARBURETOR
2 1 THROTTLE VALE
3 1 SHAFT
4 1 FUEL BOWL
5 1 FLOAT
6 1 FLOAT PIN
7 1 SCREW
9 1 MAIN FUEL JET
12 4 SCREW 14 1.6
13 1 FUEL PUMP KIT
14 5 SCREW–fuel pump 18 2.1
15 1 PLATE
16 1 GASKET
17 2 SCREW 18 2.1
18 1 COVER-fuel pump
19 1 PLUG 33 3.7
20 1 GASKET–carburetor
21 1 DIAPHRAGM
24 1 IDLE WIRE
26 1 PRIMER BRACKET
27 1 PUSHNUT
28 1 SCREW (6-32 x 3/4)
29 1 SPRING
30 2 SCREW (M5 x 8 x 12) 33 3.7
31 1 SCREW (8-32 x 1/2) Tighten Securely
32 1 PRIMER LEVER
33 1 CAM BLOCK
34 1 RETAINING CLIP
35 1 CHOKE BEZEL
36 1 PRIMER KNOB
37 1 SCREW (M5 x 30)
38 1 NUT
39 1 DECAL - Bezel Choke
40 1 ELECTRIC CHOKE
41 1 RESTRICTOR PLATE
90-827242R02 FEBRUARY 2003 Page 3A-11

Fuel System Troubleshooting

General Information
Problems thought to be caused by the fuel system may be caused by one or more of the
following six items listed below.
1. Propeller
2. Spark Plugs
3. Ignition Timing
4. Ignition Spark Voltage
5. Cylinder Compression
6. Reed Valves
Typical symptoms and solutions in troubleshooting a fuel system are shown below:
Problem: Engine Turns Over but Will Not Start or Starts Hard When Cold
Problem: Engine Idles Rough and Stalls.
Problem: Engine Runs Uneven or Surges.
Problem: Engine Will Not Accelerate.
Possible Cause Corrective Action
Improper starting procedure used. Review starting procedure as outlined in Operation
and Maintenance Manual.
Fuel tank empty or too low. Improperly mixed fuel. Check fuel in tank and replace or add whichever is
Contaminants (water,dirt, etc.) in fuel. necessary.
Fuel tank air vent closed or restricted. Check air vent on fuel tank. Air vent must be open
all the way and free from any contaminants.
Pinched, cut, restricted fuel line or loose fuel line Inspect all fuel lines and replace as needed.
connection. Tighten fuel line connections.
Dirty or restricted fuel filter. Inspect and replace or clean all fuel filters.
Choke solenoid or enrichment valve not operating. Inspect solenoid or valve and wiring. Replace as
required.
Needle and seat in carburetor that is either stuck Refer to carburetor disassembly in this section.
open (flooding) or closed (no fuel).
Improper carburetor jet, restricted jet or idle mixture Refer to carburetor adjustments in this section.
screw out of adjustment.
Improper float level. Refer to carburetor adjustments in this section.
Low fuel pump pressure. Disassemble and inspect fuel pump components.
Defective anti-siphon valve. Inspect valve and/or test engine without valve in
fuel system.
Page 3A-12 90827242R02 FEBRUARY 2003


Improperly mixed fuel. Contaminants (water, dirt, Check fuel in tank and replace if necessary.
etc.) in fuel.
Carburetor loose on intake manifold. Check tightness of carburetor nuts.
Reed block loose or gasket defective. Using a pressure oil can, apply 2-cycle oil around
reed block housing/crankcase housing matching
surfaces and carburetor base. If engine RPM
changes, tighten bolts/nuts or replace gaskets as
required.
Improperly routed or restricted bleed hoses. Refer to bleed hose routing in Powerhead section.
Damaged fuel pump diaphragm. Disassemble and inspect fuel pump components.
Carburetor mixing chamber cover leaking air. Tighten screws or replace gasket.
Off idle holes plugged. Blow with compressed air.
Main nozzle or idle nozzle air bleed holes plugged. Blow with compressed air.
Damaged reeds. Refer to Section 4 for reed inspection.
Fuel pick-up outlet tube in fuel tank cracked. Replace.
Wrong spark plug or improper spark plug gap. Install correct plug or readjust gap.
Improper spark timing. Reset timing to correct specifications.
Enrichener diaphragm leaking. Replace diaphragm.
Problem: Engine Floods

Dirt or debris are preventing inlet needle from Flush out inlet seat and clean inlet needle.
seating.
Worn inlet needle. Replace.
Punctured float. Replace.
Incorrect float setting. Reset float.
Problem: Engine Runs Too Rich

Fuel level too high. Reset float to correct level.
Carburetor floods. See preceding Engine Floods.
Idle nozzle air holes plugged. Blow out with compressed air.
Restricted air flow. Inspect cowl air inlet and carburetor for
obstructions.
Main fuel jet loose. Retighten jet.
90-827242R02 FEBRUARY 2003 Page 3A-13

Problem: Fuel Blowback Out of Carburetor

Problem: Unable to Reduce Engine RPM to Slow Idle
Chipped or broken reeds on reed block. Replace reeds.
Problem: Rough Idle
Excessive preload on reeds. Replace reeds.
Problem: Engine Runs Too Lean

Carburetor is loose. Air leaks past mixing chamber Tighten bolts securely. Tighten cover or replace
cover. gasket.
Fuel level is too low. Reset float level.
Clogged high speed jet. Inspect jet for varnish or debris and clean.
Restricted fuel flow to carburetor. Check fuel lines and filters for restricted flow.
Incorrect high speed jet. Refer to main jet chart and replace with proper jet.
Idle mixture set too lean. Adjust to run richer. Turn idle mix screw
counterclockwise.
Air leakage into fuel system. Inspect fuel line connections, hose clamps, fuel
pump and fuel outlet tube (located in fuel tank) for
loose fittings.
Anti-siphon valve restricting fuel flow. Inspect valve and/or test engine without valve in
fuel system.
Carburetor Removal
1. Loosen primer cam retaining screw.
2. Remove retaining clip.
b
a
53072
a - Screw
b - Retaining clip
Page 3A-14 90827242R02 FEBRUARY 2003

3. Push down on primer arm and pull primer knob, bezel and slide block out of bottom cowl.
4. Remove link wire from fast idle lever.
5. Disconnect fuel line from carburetor.
6. Remove carburetor mounting nuts.
7. Lift carburetor from engine. Remove bleed line from fitting in bottom of carburetor.
c dd
bb
53071
a - Primer arm
b - Primer knob
c - Bezel
d - Slide block
e - Link wire
Carburetor Installation
1. Install primer assembly components and air intake cover (on models so equipped) to
carburetor.
53065 53059
Model without Air Intake Cover Models Equipped with Air Intake Cover
90-827242R02 FEBRUARY 2003 Page 3A-15

2. Reconnect bleed hose to fitting on carburetor and install carburetor and secure
carburetor to engine with hex nuts.
3. Secure fuel line to carburetor with cable-tie.
4. Reconnect link wire to fast idle lever.
a
bb
53073
a - Link wire
b - Fast idle lever
5. Push down on primer arm and insert primer knob, bezel and slide block into primer
assembly.
6. Tighten screw to secure slide block in place.
7. Align notch in back side of bezel with tab on bottom cowl and secure bezel in place with
retaining clip.
f e
cc d
bb
53072
53071
a - Primer arm
b - Primer knob
c - Bezel
d - Slide block
e - Screw
f - Retaining clip
Page 3A-16 90827242R02 FEBRUARY 2003

Carburetor Adjustments
1. Place outboard in water.
2. Check tiller handle cable adjustment for full throttle movement in both Forward and
Reverse gears. Adjust jam nuts for proper travel and to eliminate any slack.
a - Adjustment jam nuts
INITIAL CARBURETOR ADJUSTMENTS

Idle Speed Screw (Models So Equipped)
1. Shift outboard to Neutral and place throttle twist grip to Slow.
3. Back idle speed screw off of cam follower.
4. Turn idle speed screw clockwise until it just touches cam follower, then inward an
additional 1/2 turn to slightly open throttle plate.
aa
PULL
TO
PRIME
b
a - Idle speed screw
b - Cam follower
90-827242R02 FEBRUARY 2003 Page 3A-17

NOTE: For Models NOT equipped with an idle speed screw:

1. Loosen cam locking screw.
2. Press cam follower down until it contacts throttle cam.
3. Retighten cam locking screw.
aa
cc
a - Cam locking screw

b - Cam follower
c - Throttle cam
LOW SPEED MIXTURE SCREW

1. Remove access plug from carburetor air intake cover.
2. Turn low speed mixture screw slowly clockwise until it seats lightly, then back screw out
1-1/2 to 1-3/8 turns. Turning mixture screw in tight will damage needle and seat.
3. Do not install access plug at this time.
bb
aa
a - Plug
b - Air intake cover
c - Low speed mixture screw
Page 3A-18 90827242R02 FEBRUARY 2003

IDLE WIRE ADJUSTMENT

1. Push primer/fast idle knob completely in and rotate fully counterclockwise.
2. Shift engine to Neutral.
3. Adjust screw to remove all clearance between idle wire and trigger.
4. Check fast idle speed by turning primer knob to full clockwise position. Fast idle speed
should be 1500 - 2000 RPM.
bb
a
PULL
TO
PRIME
a - Adjustment screw
b - Idle wire
IDLE ADJUSTMENT
Low speed Mixture Adjustment
1. Start engine and allow to warm up (run for several minutes). Throttle engine back to idle
for about one minute to allow RPM to stabilize.
3. With engine running at idling speed while in Forward gear, turn low speed mixture screw
counterclockwise until engine starts to load up from over-rich mixture.
4. Slowly turn low speed mixture screw clockwise until cylinders fire evenly and engine
picks up speed.
a - Low speed mixture screw
90-827242R02 FEBRUARY 2003 Page 3A-19

5. Continue turning mixture screw clockwise until too lean a mixture is obtained and engine
slows down and misfires.
6. Set low speed mixture screw halfway between rich and lean.
7. DO NOT adjust leaner than necessary to attain reasonably smooth idling. When in
doubt, set mixture slightly richer rather than too lean.
8. Install access plug into opening in carburetor air intake cover.
a - Access plug
IDLE SPEED ADJUSTMENT (MODELS EQUIPPED WITH IDLE SCREW)

1. With engine running at idle in Forward gear, make sure primer/fast idle knob is pushed
completely in and rotate fully counterclockwise to stop.
2. Adjust idle speed screw to obtain recommended idle speed. Refer to Section 1A.
a - Idle speed screw
IDLE SPEED ADJUSTMENT (MODELS NOT EQUIPPED WITH AN IDLE SPEED SCREW)
For models not equipped with an idle speed screw, the carburetor has been calibrated at
the factory to maintain an idle speed of 650 ± 75 RPM in Forward gear.
Page 3A-20 90827242R02 FEBRUARY 2003

CARBURETOR FLOAT ADJUSTMENT

Check float level by removing fuel bowl and checking level of float as shown.
If necessary, adjust float level by bending float hinge.
25.4mm
(1 in.)
Measure From
Bottom of Float
JET ORIFICE SIZE/PART NUMBER CHART

NOTE: Thread size for jets is 10-32.
JET ORIFICE SIZE/PART NUMBER CHART

Jet Orifice Jet Orifice
Part Number Part Number
Size (Inch) Size (Inch)
.040 19266040 .058 1395-7831
.042 1399-5315 .060 1395-6487
.044 1395-7394 .062 1399-4217
.046 1399-5317 .064 1399-4216
.048 1395-6246 .066 1399-4215
.050 1395-6028 .068 1395-6029
.052 1395-6359 .070 1395-6030
.054 1399-5225 .072 1395-6207
.056 1399-5213 .074 1399-3794
.076 1399-3796 .094 1395-8423
.078 1395-6680 .096 1399-6249
.080 1395-6201 .098 1395-7335
.082 1399-3518
.084 1399-3517
.086 1395-5815
.088 1395-6202
.090 1395-6247
.092 1395-5733
90-827242R02 FEBRUARY 2003 Page 3A-21

Rejetting Carburetors for High Altitude

Factory installed main fuel jets are normally adequate for proper performance up to
approximately 1524m (5000 ft) above sea level. Between 609.6m (2000 ft) and 1524m
(5000 ft) the reduction of the main fuel jets may result in improved performance and fuel
economy. Above 1524m (5000 ft), however, it is recommended that main jet size be reduced
as shown per 304.8m (1000 ft) in the following chart. RETURN TO LOWER ELEVATION:
Carburetor jet changes must be reversed to avoid a lean fuel condition when used at low
elevation.
Feet 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 1100033 12000
Meter 304.8 609.6 914.4 1219.2 1524 1828.8 2133.6 2438.4 2743.2 3048 52.8 3657.6
Jet Size
0.034 0.034 0.034 0.032 0.032 0.032 0.032 0.032 0.032 0.030 0.030 0.030 0.030
0.036 0.036 0.036 0.034 0.034 0.034 0.034 0.034 0.032 0.032 0.032 0.032 0.032
0.038 0.038 0.038 0.036 0.036 0.036 0.036 0.036 0.034 0.034 0.034 0.034 0.034
0.040 0.040 0.040 0.038 0.038 0.038 0.038 0.038 0.036 0.036 0.036 0.036 0.034
0.042 0.042 0.042 0.040 0.040 0.040 0.040 0.038 0.038 0.038 0.038 0.038 0.036
0.044 0.044 0.044 0.042 0.042 0.042 0.042 0.040 0.040 0.040 0.040 0.038 0.038
0.046 0.046 0.046 0.044 0.044 0.044 0.044 0.042 0.042 0.042 0.042 0.040 0.040
0.048 0.048 0.048 0.046 0.046 0.046 0.046 0.044 0.044 0.044 0.042 0.042 0.042
0.050 0.050 0.050 0.048 0.048 0.048 0.046 0.046 0.046 0.046 0.044 0.044 0.044
0.052 0.052 0.050 0.050 0.050 0.050 0.048 0.048 0.048 0.048 0.046 0.046 0.046
0.054 0.054 0.052 0.052 0.052 0.052 0.050 0.050 0.050 0.048 0.048 0.048 0.048
0.056 0.056 0.054 0.054 0.054 0.054 0.052 0.052 0.052 0.050 0.050 0.050 0.048
0.058 0.058 0.056 0.056 0.056 0.056 0.054 0.054 0.054 0.052 0.052 0.052 0.050
0.060 0.060 0.058 0.058 0.058 0.056 0.056 0.056 0.054 0.054 0.054 0.052 0.052
0.062 0.062 0.060 0.060 0.060 0.058 0.058 0.058 0.056 0.056 0.056 0.054 0.054
0.064 0.064 0.062 0.062 0.062 0.060 0.060 0.060 0.058 0.058 0.058 0.056 0.056
0.066 0.066 0.064 0.064 0.064 0.062 0.062 0.062 0.060 0.060 0.060 0.058 0.058
0.068 0.068 0.066 0.066 0.066 0.064 0.064 0.064 0.062 0.062 0.060 0.060 0.060
0.070 0.070 0.068 0.068 0.068 0.066 0.066 0.064 0.064 0.064 0.062 0.062 0.062
0.072 0.072 0.070 0.070 0.070 0.068 0.068 0.066 0.066 0.066 0.064 0.064 0.062
0.074 0.074 0.072 0.072 0.070 0.070 0.070 0.068 0.068 0.068 0.066 0.066 0.064
0.076 0.076 0.074 0.074 0.072 0.072 0.072 0.070 0.070 0.068 0.068 0.068 0.066
0.078 0.078 0.076 0.076 0.074 0.074 0.074 0.072 0.072 0.070 0.070 0.068 0.068
0.080 0.080 0.078 0.078 0.076 0.076 0.076 0.074 0.074 0.072 0.072 0.070 0.070
0.082 0.082 0.080 0.080 0.078 0.078 0.076 0.076 0.076 0.074 0.074 0.072 0.072
0.084 0.084 0.082 0.082 0.080 0.080 0.078 0.078 0.076 0.076 0.076 0.074 0.074
0.086 0.086 0.084 0.084 0.082 0.082 0.080 0.080 0.078 0.078 0.076 0.076 0.074
0.088 0.088 0.086 0.086 0.084 0.084 0.082 0.082 0.080 0.080 0.078 0.078 0.076
0.090 0.090 0.088 0.088 0.086 0.086 0.084 0.084 0.082 0.082 0.080 0.080 0.078
0.092 0.092 0.090 0.090 0.088 0.088 0.086 0.086 0.084 0.084 0.082 0.082 0.080
0.094 0.094 0.092 0.092 0.090 0.090 0.088 0.088 0.086 0.086 0.084 0.084 0.082
0.096 0.096 0.094 0.094 0.092 0.092 0.090 0.090 0.088 0.086 0.086 0.084 0.084
0.098 0.098 0.096 0.096 0.094 0.092 0.092 0.090 0.090 0.088 0.088 0.086 0.086
Page 3A-22 90827242R02 FEBRUARY 2003

Fuel Pump
Removal and Disassembly
IMPORTANT: Fuel pump check valve diaphragm and gasket should NOT be re-used
once the fuel pump is disassembled.
1. Remove 5 screws securing fuel pump assembly to carburetor.
2. Separate fuel pump components.
Cleaning and Inspection
1. Clean and dry all parts thoroughly.
2. Inspect pump body and base on carburetor for nicks, cracks or rough gasket surface.
3. Inspect pump check valve diaphragm. Diaphragm MUST BE flat and free from holes and
imperfections.
4. Pump body surface below check valves MUST BE flat so that check valve will seat.
Reassembly and Installation
1. Inspect all parts for serviceability.
2. Reassemble fuel pump.
3. Secure fuel pump assembly to carburetor with 5 screws. Torque screws to 3.2 Nm (18
lb-in.).
k
j
cc
d
d
e
hh f
ii
g
a - Gasket
b - Pump body
c - Spring
d - Cap
e - Gasket
f - Diaphragm
g - Pump cover
h - Lock washer (5)
i - Screw (5) [Torque screws to 3.2 Nm (18 lb-in.)]
j - Maximum spark advance screw
k - Nut
90-827242R02 FEBRUARY 2003 Page 3A-23

Primer System
The primer system provides extra fuel to the outboard whenever the primer knob is pulled
out. The primer system components should be inspected carefully for serviceability. The
diaphragm and gaskets should be inspected for cuts or abrasions. Replace accordingly. The
primer check ball and springs should be inspected for debris, varnish or rust which restrict
free movement.
SYMPTOMS OF A DEFECTIVE PRIMER SYSTEM
1. Outboard is hard to start.
a. Diaphragm is cut.
b. Primer check ball is stuck in the closed position.
c. Primer passage is plugged with debris or varnish.
2. Outboard smokes excessively at idle.
a. Primer check ball is not seated due to debris, varnish or damaged check ball spring.
a bb
e
f
gg
h
i
jj
kk
a - Seal
b - Screw (4) [Torque to 1.6 Nm (14 lb-in.)]
c - Cover
d - Diaphragm
e - Gasket
f - Spring
g - Primer bowl
h - Check ball
i - Spring
j - Gasket
k - Plug
Page 3A-24 90827242R02 FEBRUARY 2003

Servicing Sight Bowl Fuel Filter

WARNING
Exercise extreme caution when cleaning fuel filter elements. Gasoline is extremely
flammable and highly explosive under certain conditions. Always stop the engine
and DO NOT smoke or allow open flames in the area while cleaning fuel filter
elements.
CAUTION
DO NOT turn or tilt fuel filter assembly when removing or installing. PULL
STRAIGHT DOWN when removing assembly. PUSH STRAIGHT UP when installing
assembly. Turning or tilting fuel filter may break fuel line connection on filter.
The sight bowl fuel filter removes dirt and water from the fuel.
Check the sight bowl frequently and clean the filter as required.
1. Verify that the sight bowl rubber sealing ring is properly positioned in the bowl.
2. Reinstall element in filter cover.
3. Thread sight bowl onto filter cover.
4. Tighten bowl securely by hand.
33
22 22
11
44 11
55
22
66
22
77
1 - Fuel Line
2 - Cable-tie (4)
3 - Cover
4 - Filter
5 - Rubber sealing washer
6 - Sight bowl
7 - Fuel line connector
90-827242R02 FEBRUARY 2003 Page 3A-25

EMISSIONS
FUEL SYSTEM
Section 3B – Emissions
Table of Contents
Exhaust Emissions Standards . . . . . . . . . . . . 3B-1 Emissions Information . . . . . . . . . . . . . . . . . . . 3B-4
What Are Emissions? . . . . . . . . . . . . . . . . . 3B-1 Manufacturer’s Responsibility: . . . . . . . . . 3B-4
Hydrocarbons – HC . . . . . . . . . . . . . . . . . . . 3B-1 Dealer Responsibility: . . . . . . . . . . . . . . . . . 3B-5
Carbon Monoxide – CO . . . . . . . . . . . . . . .
Oxides of Nitrogen - NOx . . . . . . . . . . . . . .
3B-1
3B-2
Owner Responsibility: . . . . . . . . . . . . . . . . .
EPA Emission Regulations: . . . . . . . . . . . .
3B-5
3B-5 3
Controlling Emissions . . . . . . . . . . . . . . . . .
Stoichiometric (14.7:1) Air/Fuel Ratio . . .
3B-2
3B-2
Service Replacement Certification Label . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3B-7
3B-7
B
Outboard Hydrocarbon Emissions Reductions 3B-2 Date Code Identification . . . . . . . . . . . . . . . 3B-7
Stratified vs. Homogenized Charge . . . . . . . . 3B-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-8
Homogenized Charge . . . . . . . . . . . . . . . . . 3B-3 Decal Location: . . . . . . . . . . . . . . . . . . . . . . 3B-8
Stratified Charge . . . . . . . . . . . . . . . . . . . . . 3B-4
Exhaust Emissions 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;
gasolene 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.
90-827242R02 FEBRUARY 2003 Page 3B-1

EMISSIONS
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 two stroke 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.
Outboard Hydrocarbon Emissions Reductions

8-1/3% # Per Year Over 9 Model Years
120
100
80
60
40
20
0
96 97 98 99 2000 01 02 03 04 05 06 07 08
Page 3B-2 90-827242R02 FEBRUARY 2003

EMISSIONS
Stratified vs. Homogenized Charge

DFI engines use a stratified charge inside the combustion chamber to aid in reducing
emissions. All other models use a homogenized charge. The difference between the two
is:
Homogenized Charge
A homogenized charge has the fuel/air particles mixed evenly throughout the cylinder. This
mixing occurs inside the carburetor venturi, reed blocks and crankcase. Additional mixing
occurs as the fuel is forced through the transfer system into the cylinder.
The homogenized charge is easy to ignite as the air/fuel ratio is approximately 14.7:1.
90-827242R02 FEBRUARY 2003 Page 3B-3

EMISSIONS
Stratified Charge
A stratified charge engine only pulls air through the transfer system. The fuel required for
combustion is forced into the cylinder through an injector placed in the top of the cylinder
(head). The injector sprays a fuel/air mixture in the form of a bubble into the cylinder.
Surrounding this bubble is air supplied by the transfer system. As the bubble is ignited and
burns, the surrounding air provides almost complete combustion before the exhaust port
opens.
A stratified charge is hard to ignite, the fuel/air bubble is not evenly mixed at 14.7:1 and not
easily ignited.
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 3B-4 90-827242R02 FEBRUARY 2003

EMISSIONS
Dealer Responsibility:
When performing service on all 1998 and later 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 manufacturers 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.
Single engine exceptions may be allowed with permission from the EPA for racing and
testing.
EPA Emission Regulations:
All new 1998 and later 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 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
90-827242R02 FEBRUARY 2003 Page 3B-5

EMISSIONS
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; (shown at twice the normal size).
a hh
Emission Control 262 1998 bb

Information cc PART # 37-855211 4
This engine conforms to 1998 Model Year This engine is certified to operate on regular 87 cc
U.S. EPA regulations for marine SI engines. octane unleaded fuel (R+M)/2
Refer to Owners Manual for required maintenance. Idle Speed (in gear): 725 RPM
Exhaust Emission Control Systems: None 850 RPM (10W)
Engine Lubricants: 2-Cycle Fuel/Oil Timing: Idle: 8° BTDC WOT: 36° BTDC d
Outboard Oil NMMA/BIA Ratio: 50:1
n Certified TC-W3
Spark Plug: NGK BP8HS-15 Gap: .060” e
m
m Family: WM9XM0016210 Valve Clearance (Cold) mm
FEL: 243.11 GM/KW-HR Intake: N/A Exhaust: N/A
l ff
9.9–15 HP
g
JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC
kk jj i
a - Spark Ignition (SI)
b - Model year of engine and production decal part number
c - Type and octane of fuel used to establish emission levels
d - Timing specifications when adjustable
e - Spark plug gap in thousandths of an inch
f - Recommended spark plug for best engine performance
g - Engine horsepower rating
h - Cubic centimeter
i - Valve clearance (four stroke engines only)
j - Recommended oil/fuel ratio for best engine performance and minimal
emissions
k - Month of production (boxing month will be punched)
l - FEL: represents (Mercury Marine) statement of the maximum emissions output
for the engine family
m - Family example: W M9X M 0016 2 1 0
Model Year Regulation Application Unspecified

W=1998 M=Marine 1=PWC
X=1999 2=OB
Manufacturer Displacement Technology type
Mercury Marine Liter 1=Existing
Cubic Inch 2=New
n - Engine lubricants recommended by the manufacturer
Page 3B-6 90-827242R02 FEBRUARY 2003

EMISSIONS
Service Replacement Certification Label

IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine
outboards have a visible and legible emission certification label. If this label is
missing or damaged, contact Mercury Marine Service for replacement if appropriate.
Removal
Remove all remaining pieces of the damaged or illegible label. Do not install new label over
the old label. Use a suitable solvent to remove any traces of the old label adhesive from the
display location.
Date Code Identification
Cut and remove a “V” notch through the month of engine manufacture before installing the
new label. The month of manufacture can be found on the old label. If the label is missing
or the date code illegible, contact Mercury Marine Technical Service for assistance.
Emission Control 262 2003

Information cc PART # 37–804662 03
This engine conforms to 2003 Model Year Idle Speed (in gear): 850 RPM
U.S. EPA regulations for marine SI engines.
Refer to Owners Manual Timing: IDLE: 8° BTDC,
for required maintenance WOT: 36° BTDC
Family: 3M9XM00161CO Spark Plug: NGK BP8H-N-15

Gap: .1.52 mm (0.060 in.)
FEL: 243.11 G/MKW-HR Valve Clearance (Cold) mm

Intake: N/A Exhaust: N/A
9.9 - 15 HP
b JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC
a - “V” notch
b - Month of manufacture
90-827242R02 FEBRUARY 2003 Page 3B-7

EMISSIONS
Installation
Install the label on a clean surface in the original factory location.
Decal Location:
Model Service Part No. Location on Engine
1998 Merc/Mar 262cc (6-8 hp) 37-855577 3 Inside Rear Top Cowl
1998 Merc/Mar 262cc (9.9-15 hp) 37-855577 4 Inside Rear Top Cowl
1999 Merc/Mar 262cc (6-8 hp) 37-856985 3 Inside Rear Top Cowl
1999 Merc/Mar 262cc (9.9-15 hp) 37-856985 4 Inside Rear Top Cowl
2000 Merc/Mar 262cc (6-8 hp) 37-804659A00 Inside Rear Top Cowl
2000 Merc/Mar 262cc (9.9-15 hp) 37-804662A00 Inside Rear Top Cowl
Page 3B-8 90-827242R02 FEBRUARY 2003

Mercury Outboard Engine Service Manual

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Starting Model Year 1986

Notice to Users of This Manual

90-827242R02 FEBRUARY 2003 Page i

Cleanliness and Care of Outboard Motor

Page ii 90-827242R02 FEBRUARY 2003

Service Manual Outline

90-827242R02 FEBRUARY 2003 Page iii

How To Use This Manual

90-827242R1 MAY 1998 Page 2B-7

Revision No. 1 Section Number

Month of Printing Part of Section Letter

Year of Printing Page Number

Page iv 90-827242R02 FEBRUARY 2003

GENERAL INFORMATION & SPECIFICATIONS 1

90-827242R02 FEBRUARY 2003 Page 1A-1

Type Two-Stoke Cycle – Cross Flow

Diameter (Standard)(1994 Model)

Page 1A-2 90-827242R02 FEBRUARY 2003

GEAR Gear Ratio 2.0:1

90-827242R02 FEBRUARY 2003 Page 1A-3

Battery Rating 465 Marine Cranking Amps (MCA)

SPARK PLUG (1995 AND NEWER)

Firing Order 1-2

Stator High Speed Winding 120 - 180 Ω (BLACK/WHITE -

NOTE: *Use NGK-BPZ8H-N-10 where radio frequency interference (RFI) suppression is

Page 1A-4 90-827242R02 FEBRUARY 2003

Type Center Bowl, Integral Fuel Pump

90-827242R02 FEBRUARY 2003 Page 1A-5

Propeller Information Chart - 6 HP

Thrust Hub: 42630 1 (Forward)

Propeller Information Chart - 8 HP

Thrust Hub: 42630 1 (Forward)

Page 1A-6 90-827242R02 FEBRUARY 2003

Propeller Information Chart -9.9/10 HP

Thrust Hub: 42630 1 (Forward)

Propeller Information Chart -15 HP

Thrust Hub: 42630 1 (Forward)

90-827242R02 FEBRUARY 2003 Page 1A-7

Mercury/Quicksilver Lubricants and Sealants

Loctite 271 – Thread

19 Perfect Seal 92-34227-1 92-34227-1

25 Liquid Neoprene 92-25711-3 92-25711-3

27 Bellows Adhesive N/A 92-86166Q1

Page 1A-8 90-827242R02 FEBRUARY 2003

Tube Mercury Part Num- Quicksilver Part

127 T442 Sealant 92-862258 NA

90-827242R02 FEBRUARY 2003 Page 1A-9

Tube Mercury Part Num- Quicksilver Part

Page 1A-10 90-827242R02 FEBRUARY 2003

GENERAL INFORMATION & SPECIFICATIONS 1

90-827242R02 FEBRUARY 2003 Page 1B-1

Gearcase Lubricant Capacity

2. Grease gun 91-37299Q2

Page 1B-2 90-827242R20 FEBRUARY 2003

Inspection and Maintenance Schedule

90-827242R02 FEBRUARY 2003 Page 1B-3

Flushing The Cooling System