Service Bulletin

Bulletin No. 2018-07R1

Circulate to: Sales Manager Accounting Service Manager Technician Parts Manager

Important New Model Information—V‑8 200–300 and V‑6 175–

225
Notice
NOTICE
Revised January 2019. This bulletin supersedes the previous bulletin number 2018‑07 September 2018.
The bulletin includes revisions to the following procedures:
• Clean power
• Advanced sound control (ASC) harness/module kit ‑ V‑8 Verado only

Models Covered
Model Serial Number
V‑8 200–300 and V‑6 175–225
2B529482 and above
FourStroke/Pro XS/SeaPro/Verado Models
V‑8 250R, V‑8 300R/300R HD
1E080500 and above
Racing Models

NOTE: For additional information, view the V‑8—4.6L and V‑6—3.4L FourStroke Outboards Accessories and Rigging Guide on
MercNET>Handy Tools>Resources>Sales>US Mercury Product Guides.

Scope
Worldwide

Situation
The purpose of this bulletin is to highlight some key product information for the new V‑8 200–300 and V‑6 175–225 outboard
models, to include FourStroke, Pro XS, SeaPro, Verado, and Racing.
• Steering system requirements—CMS models
• Steering system requirements—V‑8 Verado and V‑8 SeaPro AMS models
• Battery cables
• Battery isolator wiring requirements
• Clean power
• Fuel line primer bulb
• Gauge options
• Analog gauge connection for mechanical—non‑DTS outboards
• Analog gauge connection for DTS outboards
• Speedometer—pitot connections
• Block water pressure tubing connection
• Hose connections at the rigging tube

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

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

2018-07R1 JANUARY 2019 © 2019 Mercury Marine Page 1 / 25

Important New Model Information—V-8 200–300 and V-6 175–225

• Analog block water pressure adapter kit

• Digital block water pressure sensor kits
• Digital oil level sensor kit—standard on Verado V‑8
• Water‑separating fuel filter with WIF sensor—outboard mounted
• Water‑separating fuel filter kit with WIF sensor—vessel mounted
• Advanced sound control (ASC) harness/module kit—V‑8 Verado only
• Repower harness kit—304.8 cm (10 ft)
• Rigging grommets—open option kits
• Big Tiller kits—CMS model 250 hp and below
• Propeller hub kit selection
• Driveshaft/housing conversion kits
• Gear housing removal and installation
• Special tools
• Diagnostic tool requirements
• Adaptive speed control propping with CDS G3

Steering System Requirements—CMS Models

! CAUTION
Avoid a possible steering system failure due to incorrect steering cylinder installation. Mercury heavy‑duty steering cylinders
are designed to be gearcase/propeller rotation specific. Right‑hand rotation outboards require a right‑hand steering cylinder
and left‑hand (counterrotation) outboards require a counterrotation steering cylinder. Always confirm that the correct cylinder
is paired with the correct outboard.

Mechanical Steering
IMPORTANT: Do not use mechanical steering with these engines.

Hydraulic Steering—Non Power Steering

Use Mercury heavy‑duty steering cylinders fitted with compression fittings.

Hydraulic Power Steering

Use Mercury heavy‑duty steering cylinders fitted with O‑ring face seal fittings.

Multiple Engine Steering Installations—CMS Models

Dual Outboard Steering Options
Maximum Combined 500 HP
Single Cylinder/Dual Outboard: One right‑hand HD steering cylinder mounted to the right‑hand rotation outboard, using a tie
bar kit to connect to the left‑hand (counterrotation) outboard.

Maximum Combined 600 HP

Dual Cylinder/Dual Outboard: One right‑hand HD steering cylinder mounted to the right‑hand rotation outboard, and one
left‑hand HD steering cylinder mounted to the left‑hand (counterrotation) outboard. Steering cylinders are connected using a
dual outboard tie bar kit.

Triple Outboard Steering

Triple Cylinder/Triple Outboard: One right‑hand HD steering cylinder mounted to the right‑hand rotation outboard (starboard
outboard location), one left‑hand HD steering cylinder mounted to the left‑hand (counterrotation) outboard (port outboard
location), and one HD steering cylinder from the triple outboard tie bar kit mounted to the center outboard. Steering cylinders
are connected using tie bars and hardware from the triple outboard tie bar kit.

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

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

Page 2 / 25 © 2019 Mercury Marine JANUARY 2019 2018-07R1

 Important New Model Information—V-8 200–300 and V-6 175–225

Steering System Requirements—V‑8 Verado and V‑8 SeaPro AMS Models

Important Steering Installation Guidelines
IMPORTANT: Joystick piloting has its own special requirements and is not part of this steering installation.
IMPORTANT: Do not use more than two cylinders with non‑joystick multiple engine installations. The power steering pump is
designed to support the displacement of two steering cylinders. Address concerns to your Mercury product application
engineer.
There are a few important installation guidelines that must be considered when installing the steering components on
multiengine installations. Installing the wrong steering helm and cylinder configuration may result in a less than acceptable
steering wheel lock‑to‑lock ratio.
• A 40 cc displacement helm should be used on single cylinder and liquid tie bar installations. This will yield four full turns,
lock‑to‑lock.
• A 50 cc displacement helm should be used on all dual cylinder installations rigged in parallel. This will yield 6.4 turns,
lock‑to‑lock.

Multiple Engine Steering Requirements

Tie Bar
To install the front‑mounted steering tie bars, follow the instructions included with the steering tie bar kit and observe the
following guidelines:
• Dual engine application—dual outboard tie bar kit
• Triple engine application—dual outboard tie bar kit with a Plus One tie bar kit—two steering cylinders, starboard and port
engines
• Quad engine application—dual outboard tie bar kit with two Plus One tie bar kits—two steering cylinders, starboard and
port engines

! CAUTION
Coupling multiple engines of this model with a rear‑mounted tie bar can cause cylinder distortion and premature engine
failure. Use a front‑mounted tie bar on multiple‑engine applications of this model.

Multiple Steering Cylinders

On some large/heavy dual outboard boats, the steering forces generated in extreme maneuvers may create loads that exceed
the pump's pressure capacity, where the operator may feel intermittent periods of load feedback at the steering wheel. The
steering wheel may feel hard to turn for brief periods during these extreme maneuvers. If this happens and steering
performance is deemed unacceptable for the application, a second accessory steering cylinder can be installed. When using a
second steering cylinder, the 40 cc helm should be replaced with a 50 cc helm.

Steering Hose Connections to Steering Cylinder

IMPORTANT: The hydraulic steering hose connections at the steering cylinders differ between the bolt‑on steering cylinders
used on the CMS outboards and the integrated steering cylinders used on the AMS outboards. Please refer to the following
diagrams and tables.

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

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

2018-07R1 JANUARY 2019 © 2019 Mercury Marine Page 3 / 25

Important New Model Information—V-8 200–300 and V-6 175–225

CMS Models—Hydraulic Steering

a - Helm
b - Hose to starboard side of
steering cylinder
e c - Bulkhead fitting (2)
d - Steering cylinder
c e - Hose to port side of
a steering cylinder
f - Helm to starboard side of
steering cylinder
g - Helm to port side of
steering cylinder
h h - Plug

b
d

g f
15994
h

CMS Models—Power Steering

c
b

d e

a
L PORT
R STAR
P

15257

a- Thin wrench
b- Helm hex fitting wrench size (P and T) ‑ 19 mm (3/4 in.)
c- Helm hex fitting wrench size (R and L) ‑ 16 mm (5/8 in.)
d- Hydraulic hose hex fitting wrench size (P and T) ‑ 21 mm (13/16 in.)
e- Hydraulic hose hex fitting wrench size (R STAR and L PORT) ‑ 18 mm (11/16 in.)

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

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

Page 4 / 25 © 2019 Mercury Marine JANUARY 2019 2018-07R1

 Important New Model Information—V-8 200–300 and V-6 175–225

Helm Fitting ID Mark Hose ID Mark Description

P P Pressure from pump to helm
T T Tank low pressure return to pump
R R STAR Hose connects to port side of steering cylinder
L L PORT Hose connects to starboard side of steering cylinder

AMS Models—Power Steering

c
b

d e

a
L PORT
R STAR
T
P

29204

a- Thin wrench
b- Helm hex fitting wrench size (P and T) ‑ 19 mm (3/4 in.)
c- Helm hex fitting wrench size (R and L) ‑ 16 mm (5/8 in.)
d- Hydraulic hose hex fitting wrench size (P and T) ‑ 21 mm (13/16 in.)
e- Hydraulic hose hex fitting wrench size (R STAR and L PORT) ‑ 18 mm (11/16 in.)

Helm Fitting ID Mark Hose ID Mark Description

P P Pressure from pump to helm
T T Tank low pressure return to pump
R R STAR Hose connects to starboard side of steering cylinder
L L PORT Hose connects to port side of steering cylinder

Battery Cables
Pro XS long shaft models are shipped with battery cables installed.

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

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otherwise, without the prior written consent of Mercury Marine.

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Important New Model Information—V-8 200–300 and V-6 175–225

Models without installed cables have fish lines with clips secured to the power and ground studs, to allow the cables to be
easily fed behind the intake runners. Remove the lines from the engine, prior to securing the cables to the appropriate studs.
Refer to the outboard installation manual or service manual for proper battery cable sizing.

a- Ground (–) stud

d b- Power (+) stud
c- Top of intake runners
d- Bottom of intake runners
e- Lines for feeding battery cables
behind the intake runners
a f - Clips

c e
f 63594

Battery Isolator Wiring Requirements

Model Wire Gauge
CMS/8si alternator Full load 88 amps, 4 AWG 105c wire
AMS/9si alternator Full load 116 amps, 2 AWG 105c wire

Clean Power
A 2‑pin clean power harness is shipped with CMS mechanical long shaft models only. All other models require the use of an
accessory clean power kit.

Fuel Line Primer Bulb

IMPORTANT: There is no need to install a fuel line primer bulb into the fuel system of this outboard.
These new V‑8 and V‑6 FourStroke outboard models do not use a fuel primer bulb to prime the fuel system. However, the fuel
system is not adversely affected with a primer bulb installed—as in the case of repowering an existing boat.

Gauge Options
NOTE: This outboard’s PCM has a built‑in AGI, and four analog gauge driver outputs—coolant temperature, oil pressure, trim
position, and tachometer.

Function Digital (SmartCraft) Analog

AGI is built‑into the engine's PCM and converts the digital
Tachometer Standard function on engine signal into an analog gauge output* Mercury adjustable
tachometer dial should be set to 4P
Standard sensor on engine with T‑fitting and Legris hose
Speedometer Standard sensor on engine
(black) for analog hose connection to gauge
DTS models: Standard sensor on Mechanical models: Legris hose (gray) on engine for analog
engine hose connection to mechanical gauge
Block coolant Mechanical models require optional
pressure kit: P/N 8M0142696 provides for digital DTS models require optional kit: P/N 8M0145165 provides
sensor connection. Must be used in adapters and Legris hose (gray) for analog hose connection to
conjunction with SmartCraft gauge or mechanical gauge
MFD.
Standard digital sensor on engine. AGI is built into the engine's
Trim Standard sensor on engine PCM and converts the digital trim signal into an analog gauge
output*.

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

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

Page 6 / 25 © 2019 Mercury Marine JANUARY 2019 2018-07R1

 Important New Model Information—V-8 200–300 and V-6 175–225

Function Digital (SmartCraft) Analog

Standard digital sensor on engine. AGI is built into the engine's
Block coolant
Standard sensor on engine PCM and converts the digital temperature signal into an
temperature
analog gauge output*.
Standard digital sensor on engine. AGI is built into the engine's
Engine oil pressure Standard sensor on engine PCM and converts the digital pressure signal into an analog
gauge output*.
Engine oil
Standard sensor on engine Not available
temperature
Verado model: Standard sensor on
engine Mechanical models: Optional digital oil level sensor kit P/N
Oil level Non‑Verado DTS models: Optional 8M0142265 provides audible warning. SmartCraft gauge or
digital oil level sensor kit P/N MFD required for visual warning.
8M0142265
Capable of monitoring up to two (2)
Tank level tanks. SmartCraft fuel/paddle harness Tank level gauge options are available
kit P/N 8M0075945 and senders.
Water‑in‑fuel (WIF) Standard sensor on engine provides audible warning.
Standard sensor on engine
outboard mounted SmartCraft gauge or MFD required for visual warning.
SeaPro models: Standard sensor on
SeaPro models: Standard sensor on vessel mounted filter
vessel mounted filter
Water‑in‑fuel (WIF) Non‑SeaPro models: Optional Non‑SeaPro models: Optional water‑separating fuel filter kit
vessel mounted water‑separating fuel filter kit with WIF with WIF sensor ‑ vessel mounted kit P/N 8M0135386
sensor—vessel mounted kit P/N provides audible warning. SmartCraft gauge or MFD required
8M0135386 for visual warning.

* For mechanical (non‑DTS) outboards, analog gauge outputs are wired through the 14‑pin engine wiring harness and
connected to the gauges using analog gauge harness accessory kits as listed.

Analog Gauge Connection for Mechanical (Non‑DTS) Outboards

Option 1: Analog gauge harness (non DTS 14‑pin)—connects to helm harness via 10‑pin drop/connection.
Option 2: Analog gauge harness (non DTS 14‑pin)—connects to junction box via 10‑pin adapter harness (male to male
connectors).

67773

Description Part Number

Analog gauge harness—1.524 m (5 ft) 892990T01
Analog gauge harness—3.048 m (10 ft) 892990T10

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

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

2018-07R1 JANUARY 2019 © 2019 Mercury Marine Page 7 / 25

Important New Model Information—V-8 200–300 and V-6 175–225

Description Part Number

Analog gauge harness—4.572 m (15 ft) 892990T15

62597

Description Part Number

Adapter harness 10‑pin—male to male connectors 892453A01

Analog Gauge Connection for DTS Outboards

NOTE: This outboard’s PCM has built‑in AGI and four analog gauge driver outputs—coolant temperature, oil pressure, trim
position, and tachometer.
Option 1: The analog gauge harness (DTS)—connects to engine harness via 4‑pin drop/connection at the top of the outboard’s
electrical box.

67774

Description Part Number

Analog gauge harness (DTS)—4.5 m (15 ft) 8M0095716
Analog gauge harness (DTS)—6.1 m (20 ft) 8M0095826
Analog gauge harness (DTS)—7.6 m (25 ft) 8M0095827
Analog gauge harness (DTS)—9.1 m (30 ft) 8M0095828

Option 2: The analog gauge harness (DTS)/extension harness connects to engine harness via 4‑pin drop/connection at the top
of the outboard’s electrical box. This two‑piece combination allows for the gauges to be prerigged, installed into the dash and
connected to the engine using an extension harness.

67901

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

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otherwise, without the prior written consent of Mercury Marine.

Page 8 / 25 © 2019 Mercury Marine JANUARY 2019 2018-07R1

 Important New Model Information—V-8 200–300 and V-6 175–225

Description Part Number

Analog gauge harness (DTS)—90 cm (3 ft) 4‑pin to ring terminals. Used in conjunction with
8M0150539
extension harness below.

67895

Description Part Number

4‑pin to 4‑pin extension harness—5.2 m (17 ft) 8M0150477
4‑pin to 4‑pin extension harness—8.2 m (27 ft) 8M0150478

Speedometer (Pitot) Connections

NOTE: A black Legris hose is used for pitot connections.
All models are equipped for both analog and SmartCraft digital speedometer gauge connections. A SmartCraft digital pitot
sensor is secured below the port intake runner and connected to the engine wiring harness. The Legris hose which runs from
the pitot pickup in the gearcase to the digital sensor utilizes a T‑fitting and extension hose for an analog connection. The
extension hose is routed out through the rigging grommet/rigging tube and provides connection for the analog gauge kit.
IMPORTANT: Unused analog hose connections should be inspected to ensure that the red plug is installed and that the Legris
hose is positioned neatly into the lower front cowl area.

Block Water Pressure Tubing Connection

For mechanical models: If the boat is equipped with a block water pressure gauge, the gray tubing can be used to operate the
gauge. Feed the gray tubing through the accessories opening in the rigging grommet, as shown. Remove the plug from the
coupler fitting, and make the connection to the tubing that runs to the block water pressure gauge.
If the tubing will not be used for a gauge:
1. Tuck the tubing inside the front of the engine cowling.
2. Keep the tubing clear of the throttle and shift cabling.
3. Ensure that the plug remains locked into the coupler fitting.

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

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otherwise, without the prior written consent of Mercury Marine.

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Important New Model Information—V-8 200–300 and V-6 175–225

Hose Connections at the Rigging Tube

AMS Models

a- Plug
d b- Coupler fitting
c- Water pickup tubing—black
d- Accessories opening in rigging grommet
c
b
a

67165

CMS Models

b DTS models
a - Plug
b - Coupler fitting
d c - Water pickup tubing—black
d - Accessories opening in rigging grommet

a
c 67163

Mechanical models
e a - Plug
b - Coupler fitting
c c - Water pickup tubing—black
d d - Block water pressure tubing—gray
e - Accessories opening in rigging grommet

b
a 67164

Analog Block Water Pressure Adapter Kit

NOTE: A gray Legris hose is used for block water pressure connections.
NOTE: Mechanical models are shipped standard with an analog block water pressure feature.

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otherwise, without the prior written consent of Mercury Marine.

Page 10 / 25 © 2019 Mercury Marine JANUARY 2019 2018-07R1

 Important New Model Information—V-8 200–300 and V-6 175–225

Kit allows the use of an analog block water pressure gauge on DTS outboards and provides a connection for a Legris hose
connection.

a - Water pressure hose—gray

132 cm (52 in.)
e b - 4 mm plastic coupler
a c - Plug
d - Water pressure adapter fitting
e - Connector cap

d
c

66821

Description Part Number

Analog block water pressure kit 8M0145165

a - Water pressure adapter fitting

b - Water pressure hose
b

66861

Digital Block Water Pressure Sensor Kit

NOTE: DTS models are shipped standard with a digital block water pressure feature.
Kit converts analog block water pressure equipped models to a digital system.

66808

Description Part Number

Digital block water pressure sensor kit 8M0142696

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otherwise, without the prior written consent of Mercury Marine.

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Important New Model Information—V-8 200–300 and V-6 175–225

Digital Oil Level Sensor Kit—Standard on Verado V‑8 Models

Digital oil level sensor checks engine oil at key‑up and alerts the operator if the level is low. The system is compatible with:
• VesselView 403
• VesselView 502
• VesselView 703
• VesselView 903
• MercMonitor gauges
• SC 1000 gauges

a
66067

a - Digital oil level sensor

b - Cable tie

Description Part Number

Digital oil level sensor 8M0142265

Water‑Separating Fuel Filter with WIF Sensor—Outboard Mounted

NOTE: Filter element is rated at 10 micron.
This filter is the service replacement for the standard outboard mounted inlet fuel filter.

67775

Description Part Number

Water‑separating fuel filter with WIF sensor—outboard mounted 8M0106635

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otherwise, without the prior written consent of Mercury Marine.

Page 12 / 25 © 2019 Mercury Marine JANUARY 2019 2018-07R1

 Important New Model Information—V-8 200–300 and V-6 175–225

Water‑Separating Fuel Filter Kit with WIF Sensor—Vessel Mounted

NOTE: Filter element is rated at 10 micron.

f a - Fuel filter bracket

c b - Water‑separating fuel
filter service
c replacement
a b g c - Quick‑connect fitting—
5/8" to 3/8" hose
connection (2)
d - Water drain knob with
harness connection
e - O‑ring
f - Water‑in‑fuel sensor
extension harness
g - Elbow fitting

e
d
64206

Description Part Number

Water‑separating fuel filter kit with WIF sensor—vessel mounted 8M0135386

Water‑Separating Fuel Filter Service Replacement—Vessel Mounted

64334

Description Part Number

Water‑separating fuel filter service replacement—vessel mounted 8M0126144

Advanced Sound Control (ASC) Harness/Module Kit—V‑8 Verado Only

ASC uses an electronically controlled valve in the engine’s idle relief system to bypass one of the mufflers and create a sportier
sound when desired by the user.
There are two preferred ways to control it:
1. Via a SmartCraft display—VesselView 403/502/703/903, SC1000, or MercMonitor.

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Important New Model Information—V-8 200–300 and V-6 175–225

2. Via a control module wired to a helm‑mounted rocker switch.

b a 66444

a - Harness/module
b - Cable ties (4)

Description Part Number

Advanced sound control harness/module kit 8M0143359

Rocker Switch
This kit does not include a switch. Mercury Marine recommends using a three‑position momentary rocker switch to connect to
the advanced sound control (ASC) module. The switch should meet the following specifications:
• Contacts: momentary DPST (double pole single throw), (ON)‑OFF‑(ON)
• Rating: 0.4 VA at 24 VDC (Max) resistive or greater
• Illumination: yes (LED or incandescent) (color customer choice)
• Type: rocker or toggle or rotary
• Terminals: 0.25 in. quick‑connect spade
Mercury Marine offers a generic switch to be used in conjunction with the ASC harness/module kit listed. This switch meets all
the listed requirements, but may not match the style of switches used on the boat's dash panel.

8 1 2 3 68597

Rocker switch DPST (double pole single throw), (ON)-OFF-(ON)

Pin Function ASC Module Wire Color

1 Switch output 1 (ASC off) Purple/yellow
2 Power input Purple
3 Switch output 2 (ASC on) Purple/black
4 Not used N/A
5 Not used N/A
6 Not used N/A
7 Lamp module sense ground White/black
8 Lamp power input Purple
9 Not used N/A
10 Not used N/A

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 Important New Model Information—V-8 200–300 and V-6 175–225

68599

Description Part Number

Rocker switch DPST (double pole single throw), (ON)‑OFF‑(ON) 8M0155419

Repower Harness Kit—304.8 cm (10 ft)

NOTE: Extension connections are not allowed in the rigging tube or inside the cowl.
The components in this kit are to be used to extend the existing wiring harnesses during a repower. This is done to be certain
that no connections are to be made within the cowling of the motor. All harnesses to the engine wiring connections are to be
made at the engine's electrical panel and covered with the electrical panel cover.

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otherwise, without the prior written consent of Mercury Marine.

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Important New Model Information—V-8 200–300 and V-6 175–225

Description Part Number

Repower harness kit 8M0145987

h
66973

a- 4‑pin depth extension harness

b- 2‑pin clean power extension harness
c- 2‑pin water‑in‑fuel extension harness
d- 6‑pin fuel/paddle wheel extension harness
e- 14‑pin data cable extension harness
f- 10‑pin SmartCraft extension harness
g- 3‑pin power steering extension harness
h- 10‑pin male‑to‑male gender adapter

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 Important New Model Information—V-8 200–300 and V-6 175–225

Rigging Grommets—Open Option Kits

IMPORTANT: A rigging hose is required when using this open style rigging grommet. The use of the rigging adapter and
rigging grommet is mandatory.

67553

Ref. Description Part Number

1 Open grommet for CMS mechanical models 8M0146953
2 Open grommet for CMS DTS models 8M0146954
3 Open grommet for AMS models 8M0146955

Big Tiller Kits—CMS Model 250 hp and Below

Description Part Number
Big Tiller—CMS/mechanical with power steering 8M0133491
Big Tiler—CMS/DTS with power steering 8M0133492
Throttle and shift cable kit—CMS/mechanical with two cables at 88.9 cm (35 in.) long 8M0141907

Propeller Hub Kit Selection

Propeller Shaft Good Better Best
Flo‑Torq II (175–300 HP) Flo‑Torq IV (175–200 HP) SSR hub (175–300 HP)
1 inch
835257K 6* 835257K10 8M0101602

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Important New Model Information—V-8 200–300 and V-6 175–225

Propeller Shaft Good Better Best

Flo‑Torq Solid (175–200 HP) SSR hub (175–300 HP)
1.25 inch N/A
840389K06 8M0101601

* Hub kit included with most propellers.

Driveshaft/Housing Conversion Kits

Order both a driveshaft housing conversion (spacer) kit and a matching driveshaft conversion kit per each installation. The
maximum extension length available is extra, extra long (XXL), measuring 76.2 cm (30 in.). The XXL conversion option cannot
be installed on a V‑8 300 hp CMS outboard; however it can be installed on the V‑8 300 hp SeaPro CMS model.

Driveshaft Housing Conversion (Spacer) Kits*

Description Part Number
Driveshaft housing spacer kit ‑ 12.7 cm (5 in.) Black 8M0142779
Driveshaft housing spacer kit ‑ 12.7 cm (5 in.) Silver 8M0147047
Driveshaft housing spacer kit ‑ 25.5 cm (10 in.) Black 8M0142787
Driveshaft housing spacer kit ‑ 25.5 cm (10 in.) Silver 8M0147046

67884

Driveshaft Conversion Kits*

Description Part Number
4.8 in. gearcase long shaft ‑ 50.8 cm (20 in.) 8M0146062
4.8 in. gearcase extra long shaft ‑ 63.5 cm (25 in.) 8M0146063
4.8 in. gearcase extra, extra long shaft ‑ 76.2 cm (30 in.) 8M0146064
5.4 in. gearcase long shaft ‑ 50.8 cm (20 in.) 8M0146065
5.4 in. gearcase extra long shaft ‑ 63.5 cm (25 in.) 8M0146066
5.4 in. gearcase extra, extra long shaft ‑ 76.2 cm (30 in.) 8M0146067

67885

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

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

Page 18 / 25 © 2019 Mercury Marine JANUARY 2019 2018-07R1

 Important New Model Information—V-8 200–300 and V-6 175–225

Gear Housing Removal and Installation

NOTE: It is not necessary to drain the oil sump when removing the gear housing.
IMPORTANT: The XL and XXL models use a driveshaft housing spacer which will come off with the gear housing. Be careful
not to drop or lose the driveshaft housing spacer on these models.

Gear Housing Installation

1. On right‑hand rotation gearcases, use the shift shaft tool to rotate the shift shaft counterclockwise into the front (forward)
gear. For left‑hand rotation gearcases, use the shift shaft tool to rotate the shift shaft clockwise into the front (reverse) gear.
NOTE: It may be necessary to rotate the propeller shaft to ensure that the clutch is engaged.

a - Shift shaft in neutral position

66729

Shift shaft handle tool 8M0127025

2. Ensure that the notch on the shift shaft coupler aligns with the notch on the shift actuator output shaft.

a - Notch on shift actuator coupler

b - Notch on shift actuator output shaft

b
a

65132

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

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

2018-07R1 JANUARY 2019 © 2019 Mercury Marine Page 19 / 25

Important New Model Information—V-8 200–300 and V-6 175–225

3. On right‑hand rotation gearcases, use a 15 mm wrench to rotate the shift actuator coupler so the notch on the coupler is
aligned with the "F" marking on the shift actuator. For left‑hand rotation gearcases, use a 15 mm wrench to rotate the shift
actuator coupler so the notch on the coupler is aligned with the "R" marking on the shift actuator.

a- Shift actuator coupler

b- Tab on shift actuator coupler
c- "F" marking on shift actuator
d- Wrench

F
d
c
b
a
65127

a- Shift actuator coupler

b- Tab on shift actuator coupler
c- "R" marking on shift actuator
d- Wrench
c
R

a
d
65128
4. Position the gear housing and spacer if equipped, so the driveshaft is protruding into the driveshaft housing.
5. Move the gear housing up toward the driveshaft housing while aligning the water pump coupler to the water tube and the
shift shaft into the shift shaft actuator coupler.
NOTE: If the driveshaft splines will not align with the crankshaft splines, rotate the propeller shaft slightly to reposition the
splines.
6. Secure the gear housing assembly to the driveshaft housing.

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

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

Page 20 / 25 © 2019 Mercury Marine JANUARY 2019 2018-07R1

 Important New Model Information—V-8 200–300 and V-6 175–225

Special Tools
Rigging
Lifting Strap 883705T01

Use with an overhead hoist to lift an engine.

67021

Data Cable Puller 888462A 1

Attaches to end of the DTS data harness to aid in pulling harness through
4618 boat. Prevents damage to the DTS data harness.

Transom Drilling Fixture 91‑ 98234A 2

Aids in engine installation by acting as a template for engine mounting

holes.

5489

Fuel Pressure Gauge Kit 91‑881833A03

Tests the fuel pump pressure; can be used to relieve fuel pressure.

2807

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

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

2018-07R1 JANUARY 2019 © 2019 Mercury Marine Page 21 / 25

Important New Model Information—V-8 200–300 and V-6 175–225

Battery/Clean Power Service Tool Harness 91‑8M0147078

The harness is specifically designed to assist with

the outboard engine installation onto the boat
transom. When the battery/clean power service tool
harness is installed, use the cowl mounted trim
switch to change the transom brackets/mount cradle
angle so it is better aligned—parallel with the boat
transom. The battery/clean power service tool
harness can be used on any outboard or
MerCruiser power package which utilizes a clean
battery power source.

67114

Maintenance
Crankcase Oil Pump 802889A1

Aids in the removal of engine oil without draining the crankcase.

11591

Oil Drain Hose 8M0129230

Aids in the removal of engine oil without draining the crankcase. Connect to
the crankcase oil pump.

64627

Oil Filter Wrench 91‑889277

Aids in the removal of the oil filter. Cup size: 76mm x 14 flute.

5221

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

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

Page 22 / 25 © 2019 Mercury Marine JANUARY 2019 2018-07R1

 Important New Model Information—V-8 200–300 and V-6 175–225

Alternator Belt Shoe 8M0146862

Aids in the installation and removal of the alternator belt on V‑8 and V‑6
FourStroke outboards. Tool ID number 8M0140323.

66881

Flywheel Rotation Tool 8M0146861

Aids in the manual rotation of the flywheel, especially for alternator belt
removal and installation. Tool ID number 8M0144583.

66882

Diagnostic Tool Requirements

a

d 65112

a- Mercury Marine CDS G3 license key

b- CDS G3 SmartCraft diagnostic interface
c- CAN‑P/CAN‑H adapter harness
d- G3 engine harness adapter with resistor

Description Part Number

CDS G3 interface kit 91‑8M0138392
Mercury Marine CDS G3 2018 license key 90‑8M0138391

The V‑8 200–300 and V‑6 175–225 FourStroke outboards require CDS G3 2018 update 3 or greater. Along with the standard
data fault support in this version/update, the following active diagnostics are also supported for this outboard:
• Injector pulse test
• Ignition spark gap test
• Tachometer output test
• Fuel pump output test
• IAC output test

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

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otherwise, without the prior written consent of Mercury Marine.

2018-07R1 JANUARY 2019 © 2019 Mercury Marine Page 23 / 25

Important New Model Information—V-8 200–300 and V-6 175–225

• Horn output test

• Cylinder misfire test
• Smart start test
To connect the CDS G3 SmartCraft interface cable to the engine, you must remove the yellow resistor cap from below the
electrical box cover and replace it with the SmartCraft interface adapter harness P/N 8M0046081. The adapter harness
contains the proper termination for the CAN bus circuit. Proper termination is required to ensure reliable communication. The
adapter allows the SmartCraft diagnostic interface to connect directly to the 10‑pin connector on the engine.

a - SmartCraft diagnostic interface adapter with resistor P/N

b 8M0046081
b - Resistor cap from engine

67689

Adaptive Speed Control Propping with CDS G3

A special propping procedure using CDS G3 should be used for optimum propping. An informative video can be found at:
https://p.widencdn.net/v7mcw2/ASC‑Propping.
1. Install the best guess propeller.
2. Connect CDS G3 to the engine, and monitor the following values:
• RPM ‑ engine speed. In this example, for a new boat with a new engine, the ideal RPM is at the upper end of the
RPM range.
• DemandLinear ‑ requested handle position. This should be at 100% at wide‑open throttle. If this value is not at 100%
when the handle is in the full forward position, the throttle cable needs to be adjusted—mechanical engine, or the
helm configuration needs to be performed—DTS engine.
• DemandLinear_with_Guardian ‑ software controlled limit with any engine protection/Guardian limits applied. This
value should also be at 100% when underway and with the handle in the full forward position. If this value is less than
the DemandLinear value, check faults for Guardian cause and correct the issue.
• Demand ‑ the final demand value requested by the software. If the engine is propped correctly, with engine speed at
wide‑open throttle falling within the operating range at optimum trim, this value should be at 100%.

65614

3. Run the engine with the handle at wide‑open throttle (100% DemandLinear) at optimum trim. Use the following chart to aid
in final propeller selection.

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

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

Page 24 / 25 © 2019 Mercury Marine JANUARY 2019 2018-07R1

 Important New Model Information—V-8 200–300 and V-6 175–225

Scenario Engine Speed—See Note 1

Within
At or just above At or just below
Description < 5,200 RPM operating > 6000 RPM
5,200 RPM 6,000 RPM
range
Decrease Consider a
Consider a
DemandLinear = 100% propeller pitch slightly
slightly
DemandLinear with until engine No change higher pitch
lower pitch N/A
Guardian = 100% speed needed. propeller.
propeller.
Demand = 100% falls within See Notes 3
See Note 2.
operating range. and 4.
Increase
DemandLinear = 100% propeller
DemandLinear with pitch until engine
N/A N/A N/A N/A
Guardian = 100% speed falls
Demand < 100% within
operating range.
DemandLinear < 100%
Adjust throttle cable or reconfigure DTS handle so that 100% DemandLinear can be
with throttle lever at
reached.
maximum
DemandLinear = 100%
DemandLinear with Check faults for cause of Guardian condition.
Guardian < 100%

Notes from the Table:

1. The range of 5,200–6,000 RPM is an example only. Actual RPM ranges vary by model. Refer to the applicable
specifications for your particular engine model.
2. Lowering the pitch of the propeller will increase the engine speed above the 5,200 RPM lower threshold, to account for
variations in loading and ambient conditions.
3. Increasing the pitch of the propeller will decrease the engine speed below the 6,000 RPM upper threshold, to account for
variations in loading and ambient conditions.
4. Demand may be slightly less than 100%.

Adaptive Speed Control Propping without CDS G3

IMPORTANT: Boat propping can be performed using the normal method used for Mercury Outboards. To achieve optimum
propeller selection, however, follow the Adaptive Speed Control Propping with CDS G3 procedure.
IMPORTANT: To operate the engine at full throttle before the break‑in period is complete, follow this procedure.
1. Start the engine and shift into forward gear.
2. Slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM).
3. Watch all gauges for normal readings.
4. When the engine reaches normal operating temperature, run the boat up on plane.
5. Advance the engine RPM—in 200 RPM increments, until the engine reaches its maximum rated RPM. Refer to the
appropriate outboard owner’s manual or service manual for the engine's full throttle RPM range.
6. To test if the correct propeller has been installed, operate the boat (with normal load onboard) at WOT and check RPM
with an accurate tachometer. The engine RPM should be near the top of the specified range so that, under a heavy load,
the engine speed will not fall below specifications. If the engine speed is too high, replace the propeller with a higher pitch
propeller. Normally a 25 mm (1 in.) propeller pitch change causes an RPM change of 150 RPM.
7. Return to idle speed.
8. Shut off the engine.

Operational Note
Depending on the model version CMS or AMS, a noticeable noise may be emitted from the outboard’s electronic actuators
during a key off, tilt switch actuation. To allow the outboard to be tilted with the key in the off position, the PCM is momentarily
turned on with the tilt switch. When the PCM turns on, the actuators will cycle and create a clicking or a buzzing sound. The
noise created by this actuator cycling is considered normal operation.

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

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

2018-07R1 JANUARY 2019 © 2019 Mercury Marine Page 25 / 25