Mercury 6, 8, 15, 9.9, 10 Service Manual

Download

6/8/9.9/10/15

90-827242R02 February 2003

Starting Model Year 1986

6/8/9.9/10/15

Starting Model Year 1986

Serial Number 0A197112 and Up (USA)

09503295 and Up (Belgium)

Notice

Throughout this publication, Dangers, Warnings and Cautions (accompanied by the International HAZARD Symbol

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.

) are used to alert the mechanic to special instructions

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

A - Specifications B - Maintenance C - General Information D - Outboard Installation

Section 2 - Electrical and Ignition

A - Ignition System B - Charging & Starting System C - Timing/Synchronizing & Adjusting D - Wiring Diagrams

Section 3 - Fuel System

A - Fuel Delivery System B - Emissions

Section 4 - Powerhead Section 5 - Mid-Section

A - Clamp/Swivel Brackets and Driveshaft Housing B - Power Trim

Section 6 - Lower Unit Section 7 - Attachments/Control Linkage

A - Throttle/Shift Linkage (Tiller Handle Shift Models) B - Throttle/Shift Linkage (Side Shift Models) C - Tiller Handle

Section 8 - Manual Starter

General Information & Specifications

Electrical and Ignition

Fuel System

Powerhead

Mid-Section

Lower Unit

Attachments/ Control Linkage

1 2 3 4 5 6 7

Manual Starter

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 P ARTS 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

Revision No. 1

Month of Printing

Year of Printing

Page 2B-7

Section Number

Part of Section Letter

Page Number

Page iv 90-827242R02 FEBRUARY 2003

SPECIFICATIONS

GENERAL INFORMATION & SPECIFICATIONS

Section 1A – Specifications

Table of Contents

General Specifications 1A-1. . . . . . . . . . . . . . . . . . .

Propeller Information Chart - 6 HP 1A-6. . . . . . . . .

Propeller Information Chart - 8 HP 1A-6. . . . . . . . .

General Specifications

Model 6 Model 8 Model 8 Sailmate

PERFORMANCE

(HP)

Model 9.9 Model 9.9 Sailpower XR/MAG/Viking10 Model Sea Pro/Marathon 10 Model 15 Model Sea Pro/Marathon 15

Propeller Information Chart -9.9/10 HP 1A-7. . . . .

Propeller Information Chart -15 HP 1A-7. . . . . . . .

Mercury/Quicksilver Lubricants and Sealants 1A-8

Models 6/8/9.9/10/15

4.5 (6)

5.9 (8)

7.4 (9.9)

7.5 (10)

11.2 (15)

OUTBOARD

WEIGHT

FUEL SYSTEM

Manual Start

6 8 8 Sailmate

9.9

9.9 Sailpower XR/MAG/Viking10 Sea Pro/Marathon 10 15 Sea Pro/Marathon 15

Electric Start

6 8

9.9

9.9 Sailpower 15

Recommended Gasoline

Recommended Oil Ratio

Fuel Tank Capacity 6/8/9.9/Sailpower, XR/MAG10 10 Sea Pro Marathon/15

33.1 kg (73.0 lb)

33.8 kg (74.5 lb)

34.2 kg (76.5 lb)

33.8 kg (74.5 lb)

34.0 kg (75.0 lb)

36.1 kg (79.5 lb)

36.7 kg (81.0 lb)

37.7 kg (83.0 lb)

37.0 kg (81.5 lb)

Automotive Unleaded

with a Minimum Pump Posted

Octane Rating of 86

2 Cycle Outboard Oil

25:1 (During break-in)

50:1 (After break-in)

12.0 L, 2.7 Imp Gal., 3.2 U.S. Gal.

25.0 L, 5.5 Imp Gal., 6.6 U.S. Gal.

90-827242R02 FEBRUARY 2003 Page 1A-1

SPECIFICATIONS

CYLINDER

BLOCK

CYLINDER

BORE

Type Displacement (1994 Model)

6 8

9.9

9.9 Sailpower 10 Sea Pro/Marathon XR10/MAG10 15

Displacement (1995 and Newer)

9.9

9.9 Sailpower 10 Sea Pro/Marathon XR/MAG/Viking 10 15 15 Sea Pro/Marathon

Diameter (Standard)(1994 Model)

6 8 8 Sailmate

9.9

9.9 Sailpower 10 Sea Pro/Marathon XR/Mag 10 15

Diameter (Standard)(1995 Model)

9.9

9.9 Sailpower 10 Sea Pro/Marathon XR/Mag/Viking 10 15

15 Sea Pro/Marathon Taper/Out of Round Maximum Bore Type

Two-Stoke Cycle – Cross Flow

209 cc (12.8 cu. in.) 209 cc (12.8 cu. in.) 209 cc (12.8 cu. in.) 209 cc (12.8 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.)

262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.)

262 cc (16.0 cu. in. 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.) 262 cc (16.0 cu. in.)

53.975 mm (2.125 in.)

60.325 mm (2.375 in.)

0.1016 mm (0.004 in.) Cast Iron

STROKE Length 45.7 mm (1.800 in.)

CRANKSHAFT

CONNECTING

ROD

PISTON

Top Main Bearing Journal Center Main Bearing Journal Bottom Ball Bearing Journal Connecting Rod Journal Runout

Piston Pin End (I.D.) Crankpin End (I.D.)

Piston Type Ring End Gap

19.1 mm (0.7517 in.)

20.6 mm (0.8108 in.)

20.0 mm (0.7880 in.)

20.6 mm (0.8125 in.)

0.076 mm (0.003 in.)

20.8 mm (0.8195 in.)

27.0 mm (1.0635 in.) Aluminum

0.25 mm - 0.46 mm

(0.010 in. - 0.018 in.)

Reed Stand Open (Maximum)

REEDS

All Models

Reed Stop Opening (Maximum)

All Models

Page 1A-2 90-827242R02 FEBRUARY 2003

0.178 mm (0.007 in.)

7.54 mm (0.296 in.)

SPECIFICATIONS

GEAR

HOUSING

MID

SECTION

FUEL

SYSTEM

Gear Ratio Gearcase Capacity Lubricant Type Forward Gear - Tooth count - Type Pinion Gear - Tooth count - Type Pinion Height Forward Gear Backlash Reverse Gear Backlash Water Pressure With Thermostat

– @ W.O.T (5000 RPM) – @ Idle (750 RPM)

W/O Thermostat

– @ W.O.T (5000 RPM) – @ Idle (750 RPM)

Transom Height Short Shaft

Long Shaft

Extra Long Shaft Steering Pivot Range Tilt Pin Positions Total Tilt Angle Allowable Transom Thickness

Fuel Recommended Gasoline Recommended Oil

Gasoline/Oil Ratio Fuel Tank Capacity

6/8/9.9/9.9 Sailpower XR/MAG/10 Sea Pro/ Marathon/15

2.0:1

200 ml (6.8 fl. oz.)

Quicksilver Gear Lube Premium Blend

26 Spiral/Bevel 13 Spiral/Bevel

Floating No Adjustment No Adjustment

34.5 - 48.3 kPa (5 - 7 PSI)

3.4 - 10.3 kPa (.5 – 1.5 PSI)

34.5 - 48.3 kPa (5 – 7 PSI) 0 - 7 kPa (0 – 1 PSI)

38 cm (15 in.) 51 cm (20 in.)

63.5 cm (25 in.) 78°

3 + 3 Shallow Water

78°

60.3 mm (2-3/8 in.)

Pre-Mixed Gasoline and Oil

Automotive Lead-Free

2 Cycle Outboard Oil

25:1 (During Break-In)

50:1 (After Break-In)

12.0 L, 3.2 U.S. Gal.

25.0 L, 6.6 U.S. Gal.

STARTING

SYSTEM

CHARGING

SYSTEM

Manual Start Electric Start

Starter Draw (Under Load) (No Load)

Alternator Output

BLACK Stator - 2 Magnet Flywheel

(8 Pole)(4 Pulses)

RED Stator - 4 Magnet Flywheel

(10 Pole)(5 Pulses)

Recoil

12 Volt 55 Amperes 15 Amperes

4 Amp. (48 Watt)

@ 6000 RPM

6 amp (72 Watt)

@ 6000 RPM

90-827242R02 FEBRUARY 2003 Page 1A-3

SPECIFICATIONS

BATTERY

IGNITION

SYSTEM

Battery Rating 465 Marine Cranking Amps (MCA)

or 350 Cold Cranking Amps (CCA)

Type

Capacitor Discharge

SPARK PLUG (1994)

6/8/9.9 10/15

NGK BP8H-N-10

NGK BP8HS-15

NGK BPZ8H-N-10*

SPARK PLUG GAP (1994)

6/8/9.9 10/15

1.0 mm (0.040 in.)

1.5 mm (0.060 in.)

SPARK PLUG (1995 AND NEWER)

6/8

9.9/10/15

NGK BP8H-N-10

NGK BP8HS-15

NGK BPZ8H-N-10*

SPARK PLUG GAP (1995 AND NEWER)

6/8

9.9/10/15 Firing Order Stator High Speed Winding

1.0 mm (0.040 in.)

1.5 mm (0.060 in.) 1-2

120 - 180 Ω (BLACK/WHITE -

GROUND)

Stator Low Speed Winding Diode Test

3200 - 3800 Ω (BLACK/YELLOW -

GROUND)

3100 – 3700 Ω (BLACK/YELLOW -

BLACK/WHITE)

Ignition Coil Resistance:

Primary Secondary

Trigger

0.02 - 0.04 Ω

8000 - 11000 Ω

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

CARBURETOR

SPECIFICATIONS

Type Idle RPM (In Gear)

6 8

9.9/9.9 Sailpower 10 Sea Pro/Marathon XR/MAG/Viking 10 15

Wide Open Throttle RPM

6 8

9.9/9.9 Sailpower 10 Sea Pro/Marathon XR/MAG/Viking 10 15

15 Sea Pro/Marathon Idle Mixture Screw (Initial Setting) Float Setting (All Models) Main Jet –

Thread size

9.9/9.9 Sailpower

10 Sea Pro/Marathon

XR/MAG 10

9.9/9.9 Sailpower

10 Sea Pro/Marathon

XR/MAG 10

15/Viking 10

15 Sea Pro/Marathon

Center Bowl, Integral Fuel Pump

650 ± 75 725 ± 50 725 ± 50 850 ± 50 725 ± 50 725 ± 50

4000 – 5000 4500 – 5500 5000 – 6000 5000 – 6000 5000 – 6000 5000 – 6000 5000 – 6000

Refer to Section 3 for Specifics

25.4 mm (1 in.) 10–32

1994 Model Year

.042 .046 .052 .064 .052 .066

1995 and Newer

.042 .046 .048 .052 .052 .072 .072

Idle

TIMING

SPECIFICATIONS

6 8/8 Sailmate

9.9/9.9 Sailpower 10 Sea Pro/Marathon XR/MAG/Viking 10 15 15 Sea Pro/Marathon

8° BTDC ± 1° 8° BTDC ± 1° 8° BTDC ± 1° 8° BTDC ± 1° 8° BTDC ± 1° 8° BTDC ± 1° 8° BTDC ± 1°

Maximum BTDC @ 4500 RPM – All Models

90-827242R02 FEBRUARY 2003 Page 1A-5

36° BTDC

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

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

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)

Pitch No. Of

Blades

Material Typical Gross

Boat WGT.

(LBS)

Typical Boat

Length

Thrust

Speed

Range

(MPH)

3-10 48-828150A12

Propeller Part

Number

Propeller Information Chart - 8 HP

Wide Open Throttle RPM: 4500-5500 Recommended Transom Height: 15″, 20″, 25″ Right Hand Rotation Standard Gear Reduction: 2:1

Diameter

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 9-3/4″ 6-1/2″ 3 Alum. 1400+ High Reverse

9-3/4″ 5-1/2″ 3 Alum. 1700+ Workboat 1-10 48-828148A12

Thrust Hub: 42630 1 (Forward) Propeller Drive Hub: 827598T Diffuser Ring: 42594 (Aluminum)

Pitch No. Of

Blades

Material Typical Gross

Boat WGT.

(LBS)

Typical Boat

Length

Thrust

Speed

Range

(MPH)

4-12 48-828150A12

Propeller Part

Number

Page 1A-6 90-827242R02 FEBRUARY 2003

Propeller Information Chart -9.9/10 HP

Wide Open Throttle RPM: 5000-6000 Recommended Transom Height: 15″, 20″, 25″ Right Hand Rotation Standard Gear Reduction: 2:1

SPECIFICATIONS

Diameter

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 9-3/4″ 6-1/2″ 3 Alum. 1400+ High Reverse

9-3/4″ 5-1/2″ 3 Alum. 1700+ Workboat 1-13 48-828148A12

Thrust Hub: 42630 1 (Forward) Propeller Drive Hub: 827598T Diffuser Ring: 42594 (Aluminum)

Pitch No. Of

Blades

Material Typical Gross

Boat WGT.

(LBS)

Typical Boat

Length

Thrust

Speed Range

(MPH)

5-15 48-828150A12

Propeller Part

Number

Propeller Information Chart -15 HP

Wide Open Throttle RPM: 5000-6000 Recommended Transom Height: 15″, 20″, 25″ Right Hand Rotation Standard Gear Reduction: 2:1

Diameter

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 9-3/4″ 6-1/2″ 3 Alum. 1800+ High Reverse

Thrust Hub: 42630 1 (Forward) Propeller Drive Hub: 827598T Diffuser Ring: 42594 (Aluminum)

Pitch No. Of

Blades

Material Typical Gross

Boat WGT.

(LBS)

Typical Boat

Length

Thrust

Speed Range

(MPH)

1-15 48-828150A12

Propeller Part

Number

90-827242R02 FEBRUARY 2003 Page 1A-7

SPECIFICATIONS

Mercury/Quicksilver Lubricants and Sealants

Tube

Ref. No.

Description

Needle Bearing As-

sembly Lubricant

Dielectric Grease

Loctite 271 – Thread

Locker

Loctite 567 PST Pipe

Sealant

Loctite Master Gasket

Kit

2 Cycle Premium Out-

board Oil

Mercury Part Num-

ber

92-802868A1 N/A

92-823506-1 92-823506-1

92-809819 92-809819

92-809822 92-809822

92-12564-2 92-12564-2

92-802813A1 92-802813Q1

Quicksilver Part

Number

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

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

Bellows Adhesive N/A 92-86166Q1

Loctite 680 Retaining

Compound

92-809833 92-809833

110

Special Lubricant 101 92-802865A1 92-802865Q1

U-Joint and Gimbal

92-802870A1 92-802870Q1

Bearing Grease

Loctite 222 Thread

Locker

Loctite 242 Thread

Locker

4 Cycle 25W40 Engine

Oil

Premium Gear Lubri-

cant

High Performance

92-809818 92-809818

92-809821 92-809821

92-802837A1 92-802837Q1

92-802846A1 92-802846Q1 92-802854A1 92-802854Q1

Gear Lube

Engine Coupler Spline

Grease

92-802869A1 92-802869Q1

Anti-Corrosion Grease 92-802867A1 92-802867Q1

2-4-C with Teflon 92-802859A1 92-802859Q1

4 Stroke 10W30 Out-

board Oil

92-802833A1 92-802833Q1

114

Page 1A-8 90-827242R02 FEBRUARY 2003

Power Trim & Steering

Fluid

92-802880A1 92-802880Q1

SPECIFICATIONS

Tube

Ref. #

115

116

117

119

120

121

122

123

124

125

Description

Mercury Part Num-

ber

Quicksilver Part

Number

Premium Plus 2 Cycle

TC-W3 Outboard Oil

RTV 587 Silicone

Sealer

92-802824A1 92-802824Q1

92-809825 92-809825

Loctite 7649 Primer N 92-809824 92-809824 Storage Seal Rust In-

92-802878-56 92-802878Q56

hibitor

Corrosion Guard 92-802878 55 92-802878Q55

15W40 4-cycle Diesel

92-877695K1 92-877695Q1

Engine Oil

Extended Life Anti-

92-877770K1 92-877770K1

freeze/Coolant

Marine Engine Coolant NA 92-813054A2

Fuel System Treatment and Stabilizer

92-802876A1 92-802876Q1

Concentrate

Heat Transfer Com-

92-805701 1

pound

126

127

128

129

130

131

132

133

134

135

136

137

Liquid Gasket 92-808137 NA T442 Sealant 92-862258 NA

Loctite 5900 Ultra

92-809826 NA

Black RTV Silicone

Sealant

Loctite Gasket Remov-

92-809828 1 NA

Sealer Kit, Two Part

NA 92-65150 1

Epoxy

Anti-seize Compound 92-881091K1

Torco MTF Gear Oil 92–849864–1

Optimol Longtime PD

92–848767

Dexron III Automatic

Obtain Locally Obtain Locally

Transmission Fluid

Loctite 592 Obtain Locally Obtain Locally

Loctite Quick Tite Obtain Locally Obtain Locally Isopropyl Alcohol Obtain Locally Obtain Locally

138

139

1401

90-827242R02 FEBRUARY 2003 Page 1A-9

Hot Glue Obtain Locally Obtain Locally Loctite 609 Obtain Locally Obtain Locally Loctite 405 Obtain Locally Obtain Locally

SPECIFICATIONS

Tube

Ref. #

1411

1142

143

144

145

146

Description

Cyanacrylate Adhe-

sive

3M Permabond

#3M08155

Mercury Part Num-

ber

Obtain Locally Obtain Locally

Quicksilver Part

Loctite 262 Obtain Locally Obtain Locally Loctite 290 Obtain Locally Obtain Locally

Loctite 598 RTV Seal-

Obtain Locally Obtain Locally

ant

Insulating Compound 92–41669–1

Number

Page 1A-10 90-827242R02 FEBRUARY 2003

MAINTENANCE

GENERAL INFORMATION & SPECIFICATIONS

Section 1B – Maintenance

Table of Contents

Table of Contents 1B-1. . . . . . . . . . . . . . . . . . . . . . .

Gearcase Lubricant Capacity 1B-2. . . . . . . . . . . . .

Special Tools 1B-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and Maintenance Schedule 1B-3. . . . .

Before Each Use 1B-3. . . . . . . . . . . . . . . . . . . . .

After Each Use 1B-3. . . . . . . . . . . . . . . . . . . . . . .

Every 100 Hours of Use or Once Yearly,

Whichever Occurs First 1B-3. . . . . . . . . . . . . . .

Every 300 Hours of Use or Three Years 1B-3.

Flushing The Cooling System 1B-4. . . . . . . . . . . . .

Fuel System 1B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Line Inspection 1B-5. . . . . . . . . . . . . . . . . .

Engine Fuel Filter 1B-5. . . . . . . . . . . . . . . . . . . .

Corrosion Control Anode 1B-6. . . . . . . . . . . . . . . . .

Spark Plug Inspection 1B-6. . . . . . . . . . . . . . . . . . . .

Battery Inspection 1B-7. . . . . . . . . . . . . . . . . . . . . . .

Fuse Replacement – Electric Start Remote

Control Models 1B-7. . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Points 1B-8. . . . . . . . . . . . . . . . . . . . . . .

Gearcase Lubrication 1B-10. . . . . . . . . . . . . . . . . . . .

Gearcase Lubricant Capacity 1B-10. . . . . . . . . .

Draining Gearcase 1B-10. . . . . . . . . . . . . . . . . . .

Checking Lubricant Level and Refilling

Gearcase 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage Preparations 1B-12. . . . . . . . . . . . . . . . . . . .

Fuel System 1B-12. . . . . . . . . . . . . . . . . . . . . . . . .

Protecting External Engine Components 1B-12 Protecting Internal Engine Components 1B-12.

Gearcase 1B-12. . . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning Outboard for Storage 1B-13. . . . . . .

Battery Storage 1B-13. . . . . . . . . . . . . . . . . . . . . .

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

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.

MAINTENANCE

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.

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.

WARNING

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

Fuel System

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 det e r i o r a t i o n o r 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.

MAINTENANCE

WARNING

REMOVAL

INSTALLATION

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.

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.

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-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-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-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

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.

a-Fill/Drain Plug b-Vent plug

Checking Lubricant Level and Refilling Gearcase

1. Place outboard in a vertical operating position.

MAINTENANCE

bab

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 c omponents l isted i n t he Inspection a nd M aintenance 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

Positioning Outboard for Storage

Store outboard in an upright position to allow water to drain out of outboard.

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.

MAINTENANCE

CAUTION

90-827242R02 FEBRUARY 2003 Page 1B-13

GENERAL INFORMATION

GENERAL INFORMATION & SPECIFICATIONS

Section 1C – General Information

Table of Contents

Table of Contents 1C-1. . . . . . . . . . . . . . . . . . . . . . .

Serial Number Location 1C-1. . . . . . . . . . . . . . . . . .

Conditions Affecting Performance 1C-2. . . . . . . . .

Weather 1C-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boat 1C-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine 1C-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Following Complete Submersion 1C-5. . . . . . . . . .

Submerged While Running 1C-5. . . . . . . . . . . .

Fresh Water Submersion 1C-5. . . . . . . . . . . . . .

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.

Propeller Selection 1C-6. . . . . . . . . . . . . . . . . . . . . .

Propeller Removal/Installation 1C-7. . . . . . . . . . . .

Compression Check 1C-9. . . . . . . . . . . . . . . . . . . . .

Painting Procedures 1C-9. . . . . . . . . . . . . . . . . . . . .

Cleaning & Painting Aluminum Propellers

& Gear Housings 1C-9. . . . . . . . . . . . . . . . . . . .

Decal Application 1C-11. . . . . . . . . . . . . . . . . . . . . . . .

Decal Removal 1C-11. . . . . . . . . . . . . . . . . . . . . . .

Instructions for Wet Application 1C-11. . . . . . . . .

OGXXXXXX

19XX

XXXX

b c

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

Summer hp

Conditions

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

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.

GENERAL INFORMATION

BOTTOM

(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).

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

Engine

DETONATION

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.

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.

Damaged Piston Resulting from Detonation

Page 1C-4 90-827242R02 FEBRUARY 2003

51115

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.

GENERAL INFORMATION

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 t h r o ttle 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

Propeller Removal/Installation

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.

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.

GENERAL INFORMATION

WARNING

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.

IMPORT ANT: T o 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.

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

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.

GENERAL INFORMATION

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

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

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.

IMPORT ANT: 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.

growth, and rinse with water, if necessary.

blisters only. Feather edge all broken paint edges.

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 min i mum 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 F o r c e 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

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.

GENERAL INFORMATION

** 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

IMPORT ANT: 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

GENERAL INFORMATION & SPECIFICATIONS

Section 1D – Outboard Installation

Table of Contents

Notice to Installer and Owner 1D-1. . . . . . . . . . . . .

Boat Horsepower Capacity 1D-1. . . . . . . . . . . . . . .

Outboard Remote Control 1D-2. . . . . . . . . . . . .

Selecting Accessories For The Outboard 1D-2 Selecting Steering Cables and Remote

Control Cables 1D-2. . . . . . . . . . . . . . . . . . . . . . . . .

Installing Outboard 1D-3. . . . . . . . . . . . . . . . . . . . . .

Steering Cable and Steering Link Rod

Installation 1D-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Ride Guide Steering Cable to

the Outboard 1D-3. . . . . . . . . . . . . . . . . . . . . . . .

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.

Steering Cable Seal 1D-4. . . . . . . . . . . . . . . . . .

Steering Link Rod Installation 1D-5. . . . . . . . . .

Remote Control Installation 1D-7. . . . . . . . . . . . . . .

Shift and Throttle Cable Installation to

the Outboard 1D-7. . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Wiring Harness Connection

to Engine 1D-13. . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Cable Connections 1D-14. . . . . . . . . . . . . . .

Tilt Pin Adjustment 1D-15. . . . . . . . . . . . . . . . . . . . . .

Placing Tilt Pin in Lower Holes 1D-15. . . . . . . . .

Placing Tilt Pin in Upper Holes 1D-15. . . . . . . . .

DANGER – Immediate hazards which will result in severe personal injury or death.

WARNING – Hazards or unsafe practices which could result in severe personal injury or death.

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.

DANGER

WARNING

CAUTION

90-827242R02 FEBRUARY 2003 Page 1D-1

OUTBOARD INSTALLATION

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 t ransom 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.

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.

OUTBOARD INSTALLATION

0 - 25 mm (0 - 1 in)

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

IMPORT ANT: Before installing steering cable into tilt tube, lubricate entire cable end with 2-4-C with Teflon.

1. Lubricate the entire cable end.

90-827242R02 FEBRUARY 2003 Page 1D-3

2-4-C with Teflon

OUTBOARD INSTALLATION

2. Insert steer i n g cable end through outboard tilt tube and secure steering cable to tilt tube with steering cable attaching nut as shown. Tighten to specified torque.

a-Cable end

b-Attaching nut

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.

Steering Cable Attaching Nut Torque

47.5 Nm (35 lb-ft)

6.4mm

(.250 in.)

53400

a-Mark

b-Spacer

c-O-ring

d-Cap

e-Spacer

2. Thread cap up to the 6.4 mm (1/4 in.) mark.

53069

a-Cap

b-6.4 mm (.250 in.) mark

53067

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.

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.

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.

OUTBOARD INSTALLATION

WARNING

a-Steering bracket b-Bolt (2) c-Flat washer (2) d-Locknut (2)

Steering Bracket Nut Torque

53398

15.8 Nm (140 lb-in.)

90-827242R02 FEBRUARY 2003 Page 1D-5

OUTBOARD INSTALLATION

2. Secure steering link rod between engine steering bracket and steering cable end.

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

OUTBOARD INSTALLATION

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.

a-Retainer b-Pointed ends c-Hole

90-827242R02 FEBRUARY 2003 Page 1D-7

OUTBOARD INSTALLATION

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.

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.

53212

a-Grommet b-Cable

3. Push grommet with cable into opening in starboard bottom cowl.

OUTBOARD INSTALLATION

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.

a-Barrel b-Pin c-Retainer

90-827242R02 FEBRUARY 2003 Page 1D-9

53253

OUTBOARD INSTALLATION

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 barr e l o f t h r o ttle 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.

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

53254

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.

OUTBOARD INSTALLATION

53230

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.

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

53244

53243

OUTBOARD INSTALLATION

SECURING CABLES TO ANCHOR BRACKET

1. Position barrel retainer over barrels of control cables.

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.

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.

OUTBOARD INSTALLATION

21.6 cm (8.5 in.)

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.

Dielectric Grease

a-Remote wiring connector b-Outboard wiring harness connector c-Retainer

53236

90-827242R02 FEBRUARY 2003 Page 1D-13

OUTBOARD INSTALLATION

Battery Cable Connections

SINGLE OUTBOARD

(+)

DUAL OUTBOARD

(–)

a-Red sleeve (positive)

b-Black sleeve (negative)

c-Starting battery

1. Connect a common ground cable (wire size same as engine battery cables) between negative terminals on starting batteries.

(–)

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.

OUTBOARD INSTALLATION

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

ELECTRICAL AND IGNITION

Table of Contents

IGNITION SYSTEM

Section 2A – Ignition System

Specifications 2A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools Required 2A-2. . . . . . . . . . . . . . . . . . . . .

Electrical Components 2A-4. . . . . . . . . . . . . . . . . . . . .

Description 2A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Procedures 2A-6. . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition Troubleshooting (BLACK Stator) 2A-7. . . . .

Specifications

BLACK Stator

Stator High Speed Winding Stator Low Speed Winding

Ignition Coil Resistance:

IGNITION

SYSTEM

Readings taken @

68°F (20°C).

Primary Secondary

Trigger

RED Stator

Stator Capacitor Charging Winding Ignition Coil Resistance:

Primary Secondary

Trigger

Ignition Troubleshooting (RED Stator) 2A-8. . . . . . . .

Ignition Components Removal and

Installation 2A-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition Components Removal and

Installation 2A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 - 180 Ω (BLACK/WHITE- GROUND)

3000 - 3600 Ω (BLACK/YELLOW -

GROUND)

3100 – 3700 Ω (BLACK/YELLOW -

BLACK/WHITE)

0.02 - 0.04 Ω

8000 - 11000 Ω

6500 - 8500 Ω

370 − 445 Ω (GREEN/WHITE - WHITE/

GROUND)

0.02 - 0.04 Ω

8000 - 11000 Ω

6500 - 8500 Ω

90-827242R02 FEBRUARY 2003 Page 2A-1

IGNITION SYSTEM

Special Tools Required

1. Flywheel Holder 91-52344

91–52344

2. Flywheel Holder 91-24937A1

3. DMT 2000 Digital Multimeter 91-854009A1

54964

4. Spark Gap Board 91-850439

5. Flywheel Puller 91-83164M

55117

Page 2A-2 90-827242R02 FEBRUARY 2003

Notes:

IGNITION SYSTEM

90-827242R02 FEBRUARY 2003 Page 2A-3

IGNITION SYSTEM

Electrical Components

A – RED Stator B – BLACK Stator

Page 2A-4 90-827242R02 FEBRUARY 2003

Electrical Components (continued)

REF

IGNITION SYSTEM

QTY. DESCRIPTION lb. in. lb. ft. N·m

NO.

1 1 STATOR ASSEMBLY 2 2 SCREW (M5 x 30) 40 4.5 3 1 STATOR AUXILIARY (ELECTRIC/ALTERNATOR MODELS)

4 3 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

19 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)

SCREW (M5 x 30) 40 4.5

2 SPARK PLUG (NGK#BP8H-N-10) 6/8 2 SPARK PLUG (NGK#BPZ-8H-N-10) 2 SPARK PLUG (NGK#BP8HS-15) 9.9/15

2 SPARK PLUG (NGK#BPZ8HS-15) AR ST A-STRAP (8 IN.) AR STA-STRAP (5-1/2 IN.)

TORQUE

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

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/DV A, o r 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.

WARNING

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 Troubleshooting (BLACK Stator)

TOOL : MULTIMETER/DVA

IGNITION SYSTEM

Tested Part

Stator (BLACK/ YELLOW and BLACK/WHITE wires disconnected from switch box)

Trigger (BROWN/ YELLOW and BROWN/WHITE wires disconnected from switch box)

Tested Part

Multimeter

Wires

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

Multimeter

Connected To

BLACK/WHITE

GROUND

BLACK/YELLOW

GROUND

BLACK/YELLOW

BLACK/WHITE

BROWN/YELLOW

BROWN/WHITE

Connected To

Scale

R x 1 120 - 180

R x 100

Scale

Resistance

(ohms)

32 - 38

31 - 37

6.5 - 8.5

Resistance

(ohms)

Ignition Coils (all wires disconnected)

Tested Part

Switch Box Primary Coil

Switch Box

Stop Circuit

Stator Low

Speed

Stator High

Speed

Multimeter

Wires

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

Connected To

– Terminal

+ Terminal

GROUND

BLACK/YELLOW

GROUND

BLACK/WHITE

+ Terminal

– Terminal

Spark Plug Tower

– Terminal

Selector Position

400 VDC 125 -260

400 VDC

400 VDC 10 - 75 50 - 300

Reading At

300 - 1000 RPM

150 - 300

R x 1

R x 1000

1000 - 4000 RPM

0.02 - 0.04

8 - 11

Reading At

200 - 360

250 - 360

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

Tested Part

Stator (GREEN/ WHITE and WHITE/GREEN wires disconnected from switch boxes)

Trigger (BROWN/ YELLOW and BROWN/WHITE wires disconnected from switch boxes)

Tested Part

Ignition Coils (all wires disconnected)

Multimeter

Wires

RED

BLACK

RED

BLACK

Multimeter

RED

BLACK

RED

BLACK

Connected To

GREEN/WHITE

WHITE/GREEN

BROWN/YELLOW

BROWN/WHITE

Connected To

+ Terminal – Terminal

Spark Plug Tower

– Terminal

Scale

R x 1 370 - 445

R x 100

Scale

R x 1

R x 1000

Resistance

(ohms)

6.5 - 8.5

Resistance

(ohms)

0.02 - 0.04

8 - 11

Tested Part

Switch Box Primary Coil

Switch Box

Stop Circuit

Stator Voltage

Multimeter

Wires

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

Connected To

– Terminal

+ Terminal

BLACK/YELLOW

GROUND

GREEN/WHITE

GROUND

WHITE/GREEN

GROUND

Selector Position

400 VDC

400 VDC 150 - 330 250 - 330

Reading At

300 - 1000 RPM

125 - 320

150 - 330

Reading At

1000 - 4000 RPM

200 - 320

250 - 330

Page 2A-8 90-827242R02 FEBRUARY 2003

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.

Torque Specifications

IGNITION SYSTEM

2-4-C with Teflon

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)

67.8 Nm (50 lb-ft)

4.5 Nm (40 lb-in.)

7.9 Nm (70 lb-in.)

53053

90-827242R02 FEBRUARY 2003 Page 2A-9

IGNITION SYSTEM

Ignition Components Removal and Installation (continued)

Torque Specifications

4.0 Nm (35 lb-in.)

2.3 Nm (20 lb-in.)

No Torque; Drive Tight

Liquid Neoprene

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

53047

Page 2A-10 90-827242R02 FEBRUARY 2003

ELECTRICAL AND IGNITION

Section 2B – Charging and Starting System

Table of Contents

CHARGING AND STARTING SYSTEM

Specifications 2B-1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Battery 2B-2. . . . . . . . . . . . . . . . . . .

Battery 2B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions 2B-2. . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Engine Without Battery 2B-2. . . . . . . . .

Battery Charging System Troubleshooting 2B-3

Battery Charging System 2B-3. . . . . . . . . . . . . . . . .

(1998 And Prior) 2B-3. . . . . . . . . . . . . . . . . . . . .

Alternator Amperes Output 1998 And Prior

(Stator - 8 Pole/4 Pulse) 2B-4. . . . . . . . . . . . . .

Alternator Test (1998 And Prior) 2B-4. . . . . . . .

Rectifier Test (1998 And Prior) 2B-4. . . . . . . . .

(1999 And Newer) 2B-6. . . . . . . . . . . . . . . . . . . .

Alternator Amperes Output 1999 And Newer

(Stator - 10 Pole/5 Pulse) 2B-6. . . . . . . . . . . . .

Tachometer Module Static Test 2B-7. . . . . . . . .

Tachometer Module Running or Cranking

Test 2B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rectifier/Regulator (P/N 853358T1)

Diode Test 2B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Meter (DMT 2000 or Equivalent) 2B-10.

Analog Meter 2B-12. . . . . . . . . . . . . . . . . . . . . . . .

Starting System 2B-13. . . . . . . . . . . . . . . . . . . . . . . . .

Description 2B-13. . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting the Starting Circuit 2B-13. . . . .

Starting Circuit Troubleshooting Flow Chart 2B-14.

COMMANDER 2000 Key Switch Test 2B-16. . .

Emergency Stop Switch (Lanyard Type) 2B-17.

Push Button Stop Switch 2B-17. . . . . . . . . . . . . .

Electrical Component Removal and

Installation 2B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter Motor 2B-19. . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly 2B-19. . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Inspection 2B-20. . . . . . . . . . . . . . .

Testing Motor Armature 2B-20. . . . . . . . . . . . . . .

Starter Motor Reassembly 2B-21. . . . . . . . . . . . .

Starter Solenoid Test 2B-23. . . . . . . . . . . . . . . . . .

Flywheel Ring Gear 2B-24. . . . . . . . . . . . . . . . . . . . .

Installation 2B-24. . . . . . . . . . . . . . . . . . . . . . . . . . .

Neutral Start Switch (Electric Start Tiller Handle Shift Models) 2B-24. . .

Tiller Handle Start Button 2B-25. . . . . . . . . . . . . . . . .

Choke Solenoid 2B-26. . . . . . . . . . . . . . . . . . . . . . . . .

Installation 2B-26. . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Cables/Engine Wiring Harness

(Remote Electric Start Models) 2B-27. . . . . . . . . . . .

Battery Cables (Tiller Handle Push Button Electric Start

Models) 2B-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 2B-29. . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug Harness (Battery Charging Kit) 2B-30. . . . . . .

Installation 2B-30. . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Stop Switch (Lanyard Type) 2B-30. . . .

Installation 2B-30. . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications

STARTING

SYSTEM

CHARGING

SYSTEM

BATTERY Battery Rating 465 Marine Cranking Amps (MCA)

Manual Start Electric Start

Starter Draw (Under Load) (No Load)

Alternator Output

2 Magnet Flywheel

(8 Pole)(4 Pulses)

4 Magnet Flywheel

(10 Pole)(5 Pulses)

Recoil

12 Volt 55 Amperes 15 Amperes

4 Amp. (48 Watt)

@ 6000 RPM

6 amp (72 Watt)

@ 6000 RPM

or 350 Cold Cranking Amps (CCA)

90-827242R02 FEBRUARY 2003 Page 2B-1

CHARGING AND STARTING SYSTEM

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.

CHARGING AND STARTING SYSTEM

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.

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

CHARGING AND STARTING SYSTEM

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

Amperage outpu t c a n b e m ea s u r e d b y 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

RED to YELLOW

BLACK to GRAY

RED to either GRAY or YELLOW

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)

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.

Resistance Scale

0.65* R x 1

NO CONTINUITY R x 1000

WARNING

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 lead alternately to terminals (a) and (c).

CHARGING AND STARTING SYSTEM

Connect black meter lead to ground (d), red lead alternately to terminals (a) and (c).

No Continuity Indicated

Connect black meter lead to terminal (b), red lead alternately to terminals (a) and (c).

Connect red meter lead to terminal (b), black lead alternately to terminals (a) and (c).

No Continuity Indicated.

Continuity Indicated

Continuity Indicated.

Rectifier tests O.K.

No Continuity Indicated.

Replace Rectifier.

Continuity Indicated.

Replace Rectifier.

No Continuity Indicated.

Replace Rectifier.

Continuity Indicated.

Replace Rectifier.

Connect black meter lead to terminal (b), red lead alternately to terminals (a) and (c).

No Continuity Indicated.

Replace Rectifier.

Continuity Indicated

No Continuity Indicated

Connect red meter lead to terminal (b), black lead alternately to terminals (a) and (c).

Continuity Indicated.

Rectifier Tests O.K.

90-827242R02 FEBRUARY 2003 Page 2B-5

07300

CHARGING AND STARTING SYSTEM

(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.

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

0.5

RED to YELLOW, BLACK to YELLOW

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.

R x 1

Page 2B-6 90-827242R02 FEBRUARY 2003

Tachometer Module Static Test

DIODE



1. Disconnect GRAY, YELLOW, and YELLOW/BLACK tachometer module leads.

CHARGING AND STARTING SYSTEM

91-854009A1

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.

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

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

RED BLACK

TACHOMETER MODULE LEADS

BLACK OR GROUND GRAY

7. Set meter to .

8. Measure resistance.

METER TEST LEADS

RED BLACK

TACHOMETER MODULE LEADS

BLACK OR GROUND GRAY

Open, OUCH, or OL

METER SCALE READING (V)

0.5 - 0.9 Volts

METER SCALE READING ()

4 - 8 Mega Ohms

90-827242R02 FEBRUARY 2003 Page 2B-7

CHARGING AND STARTING SYSTEM



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

10. Measure resistance.

METER TEST LEADS

RED BLACK

TACHOMETER MODULE LEADS

BLACK OR GROUND GRAY

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.

METER TEST LEADS

RED BLACK

TACHOMETER MODULE LEADS

YELLOW BLACK OR GROUND

METER SCALE READING ()

1 - 3 Mega Ohms

METER SCALE READING ()

5.5 - 8 k Ohms

Page 2B-8 90-827242R02 FEBRUARY 2003

Tachometer Module Running or Cranking Test

OUTPUT VOLTAGE TEST

CHARGING AND STARTING SYSTEM

91-854009A1

91-89045-1

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 V oltage 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 engine ground or to the BLACK tachometor module bullet connector.

4. Crank or start engine.

5. Measure voltage.

METER TEST LEADS

RED BLACK

TACHOMETER MODULE LEAD

GRAY BLACK OR GROUND

METER SCALE READING

9 - 14 Volts

90-827242R02 FEBRUARY 2003 Page 2B-9

CHARGING AND STARTING SYSTEM

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.

1. Set meter to Ω.

BLK = Black RED = Red

YEL = Yellow

2. Connect BLACK (–) meter lead to regulator case.

3. Connect RED (+) meter lead to BLACK lead.

4. Connect BLACK (–) meter lead to regulator case.

5. Connect RED (+) meter lead to RED lead.

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

0.0 OHMS

Resistance Specification

4.28 K OHMS

Resistance Specification (Both Tests)

900 K OHMS Minimum

Page 2B-10 90-827242R02 FEBRUARY 2003

VOLTAGE SPIKE SUPRESSER

1. Set meter to .

2. Connect RED (+) meter lead to regulator case.

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

CHARGING AND STARTING SYSTEM

SCR 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. Set meter to .

2. Connect BLACK (–) meter lead to regulator case.

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 

90-827242R02 FEBRUARY 2003 Page 2B-11

CHARGING AND STARTING SYSTEM

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.

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.

BLK = Black RED = Red

YEL = Yellow

Resistance Specification

DIODE TEST

SCR TEST

100 - 400 OHMS

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  OHMS (40 K)

1. Set Ohm meter to R X 1K scale.

2. Connect RED (+) meter lead to regulator case.

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

CHARGING AND STARTING SYSTEM

STARTER MOTOR

PART NO.

50-90983A1 15 AMPS

Starter Motor Teeth

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.

NO LOAD

AMP. DRAW

NORMAL

AMP. DRAW

55 AMPS

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.

CAUTION

90-827242R02 FEBRUARY 2003 Page 2B-13

CHARGING AND STARTING SYSTEM

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

There is an o p e n circuit in the BLACK NEGATIVE battery cable between the NEGATIVE battery post and the powerhead.

• Check cable for loose or corroded connections.

• Check cable for open.

To Rectifier/Regualtor

53056

Continuity Indicated

Proceed to TEST 2, on next page.

Page 2B-14 90-827242R02 FEBRUARY 2003

CHARGING AND STARTING SYSTEM

TEST 2

a. Connect voltmeter between common engine ground and Test Point 2.

No voltage reading; proceed to TEST 3.

b. Push start switch.

TEST 3

a. Connect voltmeter between common engine ground and Test Point 3. b. Push Start Switch.

No voltage reading; proceed to TEST 4.

12 Volt Reading

Defective starter solenoid.

TEST 4

a. Connect voltmeter between common

No voltage reading; proceed to TEST 5.

engine ground and Test Point 4.

b. Push Start Switch.

TEST 5

No voltage reading; proceed to TEST 6.

Connect voltmeter between common engine ground and Test Point 5.

* Battery Voltage

12 Volt Reading*

Check BLACK ground wire for poor connection or open circuit. Reconnect ground wire to starter solenoid; proceed to TEST 7.

Electric Start Tiller Handle Model

Neutral start switch on lower engine cowl is open or BLACK or WHITE switch leads are disconnected or damaged. Proceed to TEST 7.

12 Volt Reading*

Neutral start switch is open, or YELLOW/RED wire is open between Test Points 4 and 3.

12 Volt Reading*

Defective ignition switch.

TEST 6

Connect voltmeter between common engine ground and Test Point 6.

No voltage reading; check RED wire between battery positive terminal and Test Point 6.

TEST 7

a. Connect voltmeter between common engine ground and Test Point 1. b. Push Start Switch.

No voltage reading; Defective starter 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 for poor connection or open circuit.

12 Volt Reading*

Check fuse in RED wire between test points 5 and 6. Check for open RED wire between test points 5 and 6.

12 Volt Reading*

Should hear solenoid click; proceed to TEST 8.

12 Volt Reading*

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

CHARGING AND STARTING SYSTEM

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

POSITION

OFF

RUN

START

CHOKE*

CONTINUITY SHOULD BE INDICATED AT THE FOLLOWING POINTS:

BLK BLK/YEL RED YEL/RED PUR YEL/BLK

*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.

CHARGING AND STARTING SYSTEM

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)

“OFF”

CONTINUITY

(1 Ohm or Less)

“RUN”

NO CONTINUITY

(∞)

23421

3. If meter readings are other than specified, replace push button stop switch.

90-827242R02 FEBRUARY 2003 Page 2B-17

NO CONTINUITY

(∞)

23421

CHARGING AND STARTING SYSTEM

Electrical Component Removal and Installation

Liquid Neoprene

Voltage Regulator

Rectifier

Starter Solenoid

Torque Specifications

Tighten Securely

70 lb. in. (7.9 N·m)

15 lb. in. (1.7 N·m)

30 lb. in. (3.4 N·m) 25 lb. in. (2.8 N·m)

53261

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

CHARGING AND STARTING SYSTEM

springs.

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.

53235

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

53228

53081

CHARGING AND STARTING SYSTEM

Cleaning and Inspection

1. If brushes are pitted, chipped or worn to less than 4.8mm (3/16 in.), replace brushes.

IMPORT ANT: 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.

a-Hack saw blade

b-Armature core

c-Commutator

01440

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.

a-Commutator b-Core c-Shaft

CHARGING AND STARTING SYSTEM

01441

Starter Motor Reassembly

1. Reinstall brush assembly.

e d

a-Brush b-End cap c-Fiber washer d-Metal washer e-Nut

53075

90-827242R02 FEBRUARY 2003 Page 2B-21

CHARGING AND STARTING SYSTEM

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.

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.

a-Alignment marks

b-Bottom edge of permanent magnets

Page 2B-22 90-827242R02 FEBRUARY 2003

1-5/16 in.

53082

CHARGING AND STARTING SYSTEM

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.

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:

53213

53083

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.

a-Ohmmeter leads b-12-volt supply

14354

90-827242R02 FEBRUARY 2003 Page 2B-23

CHARGING AND STARTING SYSTEM

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).

Loctite 271

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.

53240

2. Torque mounting bolts to 0.6 Nm (5 lb. in.).

a-Neutral start switch

b-Plate

c-Bolts [Torque to 0.6 Nm (5 lb. in.)]

Page 2B-24 90-827242R02 FEBRUARY 2003

53077

CHARGING AND STARTING SYSTEM

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.

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.

53076

2. The starter button harness is routed into the lower cowl through the fuel connector

access hole.

53216

a-Start button assembly b-Semi-loops c-Harness d-Fuel connector

90-827242R02 FEBRUARY 2003 Page 2B-25

CHARGING AND STARTING SYSTEM

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.).

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-Gasket

b-Solenoid plate

c-Screws [Torque to 2.0 Nm (18 lb. in.)]

Page 2B-26 90-827242R02 FEBRUARY 2003

53209

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.)

CHARGING AND STARTING SYSTEM

53066

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.

53065

a-Harness b-Battery cable/sleeve c-Opening

90-827242R02 FEBRUARY 2003 Page 2B-27

53210

CHARGING AND STARTING SYSTEM

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.

a-Clip

53068

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.

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.

a-Remote control harness

b-Engine harness

c-Retainer

Page 2B-28 90-827242R02 FEBRUARY 2003

53064

CHARGING AND STARTING SYSTEM

Battery Cables (Tiller Handle Push Button Electric Start Models)

Installation

1. Fasten harness clamp to bottom cowl with nut, washer and bolt.

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.

53067

a-Clamp b-Bracket c-Grommet d-Cables

53149

90-827242R02 FEBRUARY 2003 Page 2B-29

CHARGING AND STARTING SYSTEM

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-Harness

3. Refer to Section 2D for wiring connections.

53063

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-Stop Switch

b-Clip

3. Refer to Section 2D for wiring connections.

Page 2B-30 90-827242R02 FEBRUARY 2003

53054

53055

ELECTRICAL AND IGNITION

Section 2C – Timing, Synchronizing & Adjusting

Table of Contents

TIMING, SYNCHRONIZING & ADJUSTING

Specifications 2C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools 2C-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 2C-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side Shift Models 2C-2. . . . . . . . . . . . . . . . . . . . . . .

Specifications

MAXIMUM TIMING 36° BTDC IDLE TIMING

6/8/9.9/10/15

IDLE RPM IN FORWARD GEAR –

6 8/9.9/15 10 SEA PRO MARATHON XR/MAG/VIKING 10 15 SEA PRO MARATHON

FULL THROTTLE RPM

6 8

9.9/10/15

Tiller Handle Shift Models 2C-3. . . . . . . . . . . . . . .

Maximum Timing Adjustment 2C-4. . . . . . . . . . . .

Idle Timing Adjustment 2C-4. . . . . . . . . . . . . . . . . .

Fast Idle Adjustment 2C-5. . . . . . . . . . . . . . . . . . . .

8° BTDC ± 1°

650 ± 75 725 ± 50 850 ± 50 850 ± 50 725 ± 50

725 ± 50

4000 – 5000 4500 – 5500 5000 – 6000

SPARK PLUG (1994)

6/8/9.9 10/15

SPARK PLUG GAP

6/8/9.9 10/15

SPARK PLUG (1995 AND NEWER)

6/8

9.9/10/15

SPARK PLUG GAP

6/8

9.9/10/15

NEUTRAL FAST IDLE 1500 – 2000 RPM

NGK BP8H-N-10 NGK BP8HS-15

1.0mm (0.040 in.)

1.5mm (0.060 in.)

NGK BP8H-N-10 NGK BP8HS-15

1.0mm (0.040 in.)

1.5mm (0.060 in.)

90-827242R02 FEBRUARY 2003 Page 2C-1

TIMING, SYNCHRONIZING & ADJUSTING

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.

a-Jam nuts

TIMING, SYNCHRONIZING & ADJUSTING

53046

TIMING POINTER LOCATION

a-Timing pointer

40 30

90-827242R02 FEBRUARY 2003 Page 2C-3

Mercury 6, 8, 15, 9.9, 10 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual