Mercury 75 HP, F90 HP, 115 HP, 90 HP Installation Manual
INSTALLATION MANUAL
75, 90 AND 115 HP (4-Stroke)
NOTICE TO INSTALLER: After completing assembly, these instructions should be
placed with the product for the owner’s future use.
IMPORT ANT: If the boat is to be water tested, the operator should be familiar with the
operation procedures in the Operation and Maintenance Manual.
Electric Fuel Pump 1. . . . . . . . . . . . . . . . . . . . . . . . .
Boat Horsepower Capacity 1. . . . . . . . . . . . . . . . . .
Start in Gear Protection 2. . . . . . . . . . . . . . . . . . . . .
Selecting Accessories For The Outboard 2. . . . . .
Installation Specifications 2. . . . . . . . . . . . . . . . . . . .
Lifting Outboard 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Cable 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Link Rod 4. . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Outboard 5. . . . . . . . . . . . . . . . . . . . . . . . .
Electrical, Hoses and Control Cables 7. . . . . . . . .
Front Cowl Grommet 7. . . . . . . . . . . . . . . . . . . . . .
Electric Fuel Pump
If an electric fuel pump is used, the fuel pressure must not exceed 4 psig at the engine. If
necessary, install a pressure regulator to regulate the pressure.
Boat Horsepower Capacity
U.S. COAST GUARD CAPACITY
Remote Wiring Harness 7. . . . . . . . . . . . . . . . . . . .
Battery Cable Connections 8. . . . . . . . . . . . . . . . .
Fuel Hose 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer (Optional) Water Pick-up 9. . . . . .
75 and 90 Hp Shift Cable Installation 10. . . . . . .
75 and 90 Hp Throttle Cable Installation 12. . . . .
115 Hp Shift Cable Installation 13. . . . . . . . . . . . .
115 Hp Throttle Cable Installation 15. . . . . . . . . .
Propeller Installation 16. . . . . . . . . . . . . . . . . . . . . . .
Trim-In Stop Adjustment 17. . . . . . . . . . . . . . . . . . .
Trim Tab Adjustment 18. . . . . . . . . . . . . . . . . . . . . . .
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
Do not overpower or overload the 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.
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.
90-10216040 JANUARY 2003 Printed in U.S.A. - 2003, Mercury Marine Page 1 of 18
75, 90 and 115 (4-STROKE) INSTALLATION MANUAL
Start in Gear Protection
The remote control connected to the outboard must be equipped with a start-in-gear
protection device. This prevents the engine from starting 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
Genuine Quicksilver Parts and Accessories have been specifically designed and tested for
this outboard.
Some accessories not manufactured or sold by Quicksilver are not designed to be safely
used with this outboard or outboard operating system. Acquire and read the Installation,
Operation, and Maintenance manuals for all selected accessories.
Installation Specifications
a
a – Transom Opening – Minimum
Single Engine – 33 in. (838.2)
Dual Engines – 59 in. (1498.6 mm)
b – Engine Center Line For Dual Engine
26 in. (660mm) Minimum
a
b
Page 2 of 18
Lifting Outboard
Use Flywheel Puller/Lifting Eye (91-83164M).
Steering Cable
STARBOARD SIDE ROUTED CABLE
1. Lubricate O-ring seal and entire cable end.
75, 90 and 115 (4-STROKE) INSTALLATION MANUAL
a
a-Quicksilver 2-4-C Marine Lubricant with Teflon
2. Insert steering cable into tilt tube.
3. Torque nut to 35 lb. ft. (47.5 N·m).
Page 3 of 18
75, 90 and 115 (4-STROKE) INSTALLATION MANUAL
Steering Link Rod
Installation Note
NOTE: For ease of installation of special bolt (a) separate the front end of the bottom cowl.
1. Install steering link rod per illustration.
a
c
d
b
a-Special Bolt (10-90041) Torque to 20 lb. ft. (27.1 N·m)
b-Nylon Insert Locknut (11-34863) Torque to 20 lb. ft. (27.1 N·m)
c-Flat Washer (2)
d-Nylon Insert Locknut (11-34863) Tighten Locknut Until it Seats, Then Back Nut
Off 1/4 Turn
IMPORTANT: The steering link rod that connects the steering cable to the engine
must be fastened using special bolt (“a” - Part Number 10-90041) and self locking
nuts (“b” & “c” - Part Number 11-34863). These locknuts must never be replaced with
common nuts (non locking) as they will work loose and vibrate off, freeing the link
rod to disengage.
WARNING
Disengagement of a steering link rod can result in the boat taking a full, sudden,
sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death.
Page 4 of 18
75, 90 and 115 (4-STROKE) INSTALLATION MANUAL
Installing Outboard
Determining Recommended Outboard Mounting Height
26 in.
(660mm)
25 in.
(635mm)
24 in.
(609mm)
(e)
Outboard
Mounting
Height
e
(See NOTE
Below)
23 in.
(584mm)
22 in.
(560mm)
21 in.
(533mm)
20 in.
(508mm)
a
b
c
d
19 in.
(482mm)
NOTE: Add 5 in. (127mm) for XL models to the listed outboard mounting
height.
IMPORTANT
NOTICE TO INSTALLER
1. The outboard should be mounted high enough on the transom so that the exhaust
relief hole will stay at least 1 in. (25.4 mm) above the water line when the engine is
running at idle speed. Having the exhaust relief hole above the water line will prevent
exhaust restriction. Exhaust restriction will result in poor performance at idle.
2. However, keep in mind that the mounting height (e) of the outboard must not exceed
25 in. (635 mm) for L models, 30 in. (762 mm) for XL models. Mounting the outboard
higher may cause damage to the gear case components.
This solid line is recommended to determine the out-
a.
board mounting height.
IMPORTANT: Increasing the height of outboard generally will provide the following: 1) Less steering torque,
2) more top speed, 3) greater boat stability, but, 4) will
cause more prop “break loose” which may be particularly noticeable when planing off or with heavy load.
These broken lines represent the extremes of known
successful outboard mounting height dimensions.
b.
10
20 30 40 50 60 70 80
Maximum Boat Speed Anticipated
c.
This line may be preferred to determine outboard
mounting height dimension, if maximum speed is the
only objective.
This line may be preferred to determine outboard
d.
mounting height dimension for dual outboard installation.
Outboard mounting height (height of outboard transom
e.
brackets from bottom of boat transom). For heights over
22 in. (560mm), a propeller, that is designed for surfacing operation is usually preferred.
Page 5 of 18
75, 90 and 115 (4-STROKE) INSTALLATION MANUAL
Installing Outboard
1. Use transom drilling fixture (91-98234A2) or attach (tape) engine mounting template
(located in this manual) to boat transom.
2. Mark and drill four 17/32 in. (13.5mm) mounting holes.
3. Refer to “Determining Recommended Outboard Motor Mounting Height”, preceding,
and install outboard to the nearest recommended mounting height.
4. Fasten outboard with provided mounting hardware shown.
NOTE: The addition of the four flat washers (d) is a manufacturing running change. Outboards built before the running change will not have the flat washers.
d
b
a
c
e
a-1/2 in. Diameter Bolts (4)
b-Flat Washers(4)
c-Locknuts (4)
d-Flat Washers(4)
e-Marine Sealer - Apply to Shanks of Bolts, Not Threads
Page 6 of 18
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