90-883064R02cvr.

qxp 7/12/2006 9:01 AM Page 1

30/40 FourStroke EFI

30/40
FourStroke
Electronic
Fuel Injection

90-883064R02 JULY 2006

Starting Model Year 2002
Starting Model Year 2002
www.mercurymarine.com.au www.mercurymarine.com www.marinepower.com Starting Serial Number 0T409000
Private Bag 1420 P.O. Box 1939 (Parc Industriel de Petit-Rechain)
Dandenong South 3175 Fond du Lac, WI 54936-1939 USA B-4822 Verviers/Belgium
Victoria, Australia

©2006, Mercury Marine. All rights reserved. Printed in U.S.A. 90-883064R02 JULY 2006
Notice to Users of This Manual
Throughout this publication, Dangers, Warnings and Cautions (accompanied by the
International HAZARD Symbol ) are used to alert the mechanic to special instructions
concerning a particular service or operation that may be hazardous if performed incorrectly
or carelessly. OBSERVE THEM CAREFULLY!
These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus common sense operation,
are major accident prevention measures.

DANGER
DANGER - indicates an imminently hazardous situation that, if not avoided, will
result in death or serious injury.

WARNING
WARNING - indicates a potentially hazardous situation that, if not avoided, could
result in death or serious injury.

CAUTION
CAUTION - indicates a potentially hazardous situation that, if not avoided, may
result in minor or moderate injury or property damage. It may also be used to alert
against unsafe practices.
This 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. We reserve the right to make changes to this manual without prior
notification.
E 2005, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury
Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo,
Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort,
M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered
trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered
service mark of Brunswick Corporation.
It is assumed that these personnel are familiar with marine product servicing procedures.
Furthermore, it is assumed that they have been trained in the recommended service
procedures of Mercury Marine Power Products, including 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 marine trade of all conceivable procedures
and of the possible hazards and/or results of each method. 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.
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.
Refer to dealer service bulletins, operation maintenance and warranty manuals and
installation manuals for other pertinent information concerning the products described in
this manual.

90--883064R02 JULY 2006 Page i

Precautions
It should be kept in mind, while working on the product, that the electrical and ignition
systems 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.
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 reuse, care should be taken
to select a replacement that matches the original.

Replacement Parts
Use of parts other than the recommended service replacement parts, will void the warranty
on those parts that are damaged as a result.

WARNING
Electrical, ignition and fuel system components on Mercury Marine Power Products
are designed and manufactured to comply with U.S. Coast Guard Rules and
Regulations to minimize risks of fire or explosion.
Use of replacement electrical, ignition or fuel system components, which do not
comply to these rules and regulations, could result in a fire or explosion hazard and
should be avoided.
When servicing the electrical, ignition and fuel systems, it is extremely important
that all components are properly installed and tightened. If not, any electrical or
ignition component opening would permit sparks to ignite fuel vapors from fuel
system leaks, if they existed.

Cleanliness and Care of Product

A Mercury 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 engine that is suspended. Engines should be
attached to work stands, or lowered to ground as soon as possible.

Page ii 90--883064R02 JULY 2006

Service Manual Outline
1 - Important Information
Important Information
1
A - Specifications
B - Maintenance
C - General Information
D - Outboard Motor Installation
Electrical
2
2 - Electrical
A - Ignition
B - Charging and Starting System
C - Timing, Synchronizing and Adjusting
Electronic Fuel
Injection 3
3 - Electronic Fuel Injection
A - Theory of Operation
B - Troubleshooting and Diagnostics
C - Service Procedures
Powerhead
4
D - Emissions
4 - Powerhead
A - Cylinder Head
B - Cylinder Block/Crankcase
Mid-Section
5
C - Lubrication
5 - Mid-Section
A - Clamp/Swivel Brackets and Driveshaft Housing
Lower Unit
6
B - Power Trim
C - Manual Tilt Assist
6 - Lower Unit
A - Non-Bigfoot Gear Housing 1B226999 and Below
Attachments/
Control Linkage 7
B - Non-Bigfoot Gear Housing 1B227000 and Above
C - Bigfoot Gear Housing
7 - Attachments/Control Linkage
A - Throttle/Shift Linkage
B - Tiller Handle

90--883064R02 JULY 2006 Page iii

 Specifications

Important Information 1
Section 1A - Specifications A

Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 Mercury/Mariner 40 EFI (4-Stroke)
Propeller Information Charts . . . . . . . . . . . . . 1A-9 2.3:1 Bigfoot . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-11
Mercury/Mariner 30 EFI (4-Stroke) Special soft rubber hub propellers designed
2.00:1 Non-Bigfoot . . . . . . . . . . . . . . . . . . . . 1A-9 to reduce clutch rattle . . . . . . . . . . . . . . . 1A-11
Mercury/Mariner 40 EFI (4-Stroke) Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-12
2.00:1 Non-Bigfoot . . . . . . . . . . . . . . . . . . . . 1A-10

90-883064R02 JULY 2006 Page 1A-1

Specifications

Specifications

Models 30/40 EFI (4-Stroke)

Horsepower Model 30 22.4 kW (30 hp) @ 5750 RPM
(kW) Model 40 29.8 kW (40 hp) @ 5750 RPM
Electric
Outboard Weight
30/40 ELPT 112.7 kg (224 lbs.)
Recommended Gasoline Automotive Unleaded
Fuel with a Minimum Pump Posted
Octane Rating of 87
Oil Filter P/N 35-822626Q04
Oil Filter Wrench P/N 91-802653Q02
Engine Oil Capacity Either 3 quarts or 3 liters
Engine Oil SAE 10W-30 viscosity oil is recom-
mended for use in all temperatures.
SAE SAE SAE 25W-40 viscosity oil may be used at
F° C° 25W-40 10W-30 temperatures above 4° C (40° F).

+100 +38 Use Mercury/Quicksilver 4-Cycle Marine

Oil with the proper viscosity for the
+80 +27 expected temperature in your area (see
Oil
+60 +16 range thermometer on left). If not
available, use a premium quality 4-cycle
+40 +4
engine oil, certified to meet or exceed
+20 -7 any one of the following American
Petroleum Institute (API) service
0 -18
classifications SH, SG, SF, CF-4, CE,
CD, CDll.

Page 1A-2 90-883064R02 JULY 2006

 Specifications

Type Capacitor Discharge Ignition

Spark Plug:
Type Champion RA8HC
Gap 1.0 mm (0.040 in.)
Hex Size 16 mm (5/8 in.)
Torque 17 Nm (150 lb. in.)
Hole Size 12 mm
Firing Order 1-2-3
Ignition Timing:
@ Idle Controlled by ECM
@ 1800 - 2000 17° B.T.D.C.
@ WOT (6000 RPM) 28° B.T.D.C.
Crank Position Sensor (CPS)
Resistance 300 - 350Ω (red - white)
Ignition Coil Resistance:
0T979999 and Below
Internal Shielding 0 - 10.0 kΩ (Pin A - mounting bracket)
Electronic Spark Trigger (EST) 8.5 - 12 kΩ (Pin B - Pin C)
Secondary 3.0 - 7.0 kΩ (Pin A - coil tower)
High Tension Lead/Boot
Ignition Resistance 0.600 - 1.100 kΩ
System 0T980000 and Up
Readings taken @
Primary 0.25 Ω ± 10% (Pin D - Pin E)
20° C (68° F)
Secondary 1.0 kΩ ± 20% (Pin C and coil tower)
Electronic Spark Trigger (EST) 8.5 - 12 kΩ (Pin A - Pin B)
ECM Engine RPM Limiter
Fuel/Spark Cutout On Cylinder #2 6225 RPM
Fuel/Spark Cutout On All Cylinders 6350 RPM
ECM Overheat RPM Control Guardian is active. Power limit will vary
with level of overheat.
ECM Low Oil Pressure RPM Contol Guardian is active. Engine power is
limited to 10% of maximum
(approximately 2000 RPM).
MAT/ECT Temperature Sensor See Graph in Section 3B - EFI
Manifold Absolute Pressure (MAP) See Table in Section 3B - EFI
Sensor Resistance
Fuel Injector Resistance 10.0 - 13.5 Ω
Main Power Relay 81 - 99 Ω (Pin 85 - Pin 86)
Idle Air Control (IAC) 24 - 30 Ω between pins
Throttle Position Sensor Range
Output Voltage @ Idle 0.39 - 1.00 volts
Output Voltage @ WOT 3.66 - 4.80 volts

Charging Alternator Type: Single Phase (12 pole)

System 20 ampere Electric Alternator Output 12.6 v - 20 amperes (252 watts)
Readings taken @
(rectified/regulated)
20° C (68° F)
Stator Resistance 0.20 - 0.30 Ω (yellow-yellow)
Quicksilver Tachometer Setting “6P” or “4”

90-883064R02 JULY 2006 Page 1A-3

Specifications

Electric Start:
Starter Type Bendix
Starting Output 1.1 kW
System Ampere Draw Under:
(Load) 174.0 amperes
(No Load) 23.7 amperes
Battery Rating
Minimum Requirement 465 Marine Cranking Amperes (MCA)
or 350 Cold Cranking Amperes (CCA)
For operation below 0° C (32° F) 1000 Marine Cranking Amperes (MCA)
Battery or 775 Cold Cranking Amperes (CCA)
Ampere-Hours (Ah) Minimum
For operation above 0° C (32° F) 70
For operation below 0° C (32° F) 105
Fuel Pump Type Mechanical Water Cooled
(Plunger/Diaphragm)
Fuel
Fuel Pump:
System
Pressure 20.7 - 41 kPa (3 - 6 psi)
Fuel Tank Capacity Accessory
Fuel Injector System Batch
Idle RPM (Out Of Gear) 775 ± 25 RPM
Fuel Injection Idle RPM (In Forward Gear) 775 ± 25 RPM
Wide Open Throttle RPM (WOT) Range 5500 - 6000
Fuel Pump Pressure - Electric 290 - 303 kPa (42 - 44 psi)
Type 4-Stroke Cycle - Overhead Camshaft
Cylinder
Displacement 747 cc (45.6 cu. in.)
Block
Number of Cylinders 3
Stroke Length 75 mm (2.953 in.)
Diameter
Standard 65 mm (2.5591 in.)
Cylinder Oversize - 0.25 mm (0.010 in.) 65.25 mm (2.5689 in.)
Bore Oversize - 0.50 mm (0.020 in.) 65.5 mm (2.5787 in.)
Taper/Out of Round Maximum 0.08 mm (0.003 in.)
Bore Type Cast Iron
Piston Type Aluminum
O.D. at Skirt
Piston Standard 64.950 - 64.965 mm (2.5570 - 2.5578 in.)
Oversize - 0.25 mm (0.010 in.) 65.2 - 65.215 mm (2.5669 - 2.5675 in.)
Oversize - 0.50 mm (0.020 in.) 65.450 - 65.465 mm (2.5768 - 2.5774 in.)
Piston Piston to Cylinder Clearance 0.035 - 0.065 mm (0.0014 - .0026 in.)
Clearance
Ring End Gap (Installed)
Top 0.15 - 0.03 mm (0.006 - 0.012 in.)
Middle 0.30 - 0.50 mm (0.012 - 0.020 in.)
Rings Bottom (Oil Ring) 0.20 - 0.70 mm (0.008 - 0.028 in.)
Side Clearance:
Top 0.02 - 0.06 mm (0.0008 - 0.0024 in.)
Middle 0.02 - 0.06 mm (0.0008 - 0.0024 in.)
Compression Ratio 9.7:1
Compression Cylinder Compression 1241 - 1448 kPa (180 - 210 psi) (Peak)
Ratio (Electric Models Only, Cold Engine @
WOT)

Page 1A-4 90-883064R02 JULY 2006

 Specifications

Piston Pin Piston Pin Diameter 15.965 - 15.970 mm (0.6285 - 0.6287 in.)
Connecting Oil Clearance (Big End) 0.020 - 0.052 mm (0.0008 - 0.0020 in.)
Rod Small End Inside Diameter 15.985 - 15.998 mm (0.6293 - 0.6298 in.)
Main Bearing Clearance 0.012 - 0.044 mm (0.0005 - 0.0017 in.)
Crankshaft
Crankshaft Run-out 0.046 mm (0.0018 in.)
Camshaft Dimensions
Intake “A” 30.83 - 31.03 mm (1.214 - 1.222 in.)
Exhaust “A” A 30.83 - 31.03 mm (1.214 - 1.222 in.)
Intake “B” 25.90 - 26.10 mm (1.020 - 1.028 in.)
Exhaust “B” 25.90 - 26.10 mm (1.020 - 1.028 in.)

Run-out Limit B 0.1 mm (0.0039 in.)

Camshaft Bearing Diameter “b” 36.935 - 36.955 mm
(1.4541 - 1.4549 in.)

Camshaft

b
b b

Free Length “a” 37.85 - 39.85 mm (1.491 - 1.569 in.)

Tilt Limit “b” Less than 1.7 mm (0.060 in.)
bb

aa
Valve Spring

Compressed Pressure (Installed)

Intake 9.0 - 10.0 kg (19.8 - 22.0 lbs.)
Exhaust 9.0 - 10.0 kg (19.8 - 22.0 lbs.)
Tilt Limit (Intake & Exhaust) 1.1 mm (0.043 in.)
Direction of Winding (Intake & Left Hand
Exhaust)

90-883064R02 JULY 2006 Page 1A-5

Specifications

Warp Limit 0.1 mm (0.004 in.)

* Lines indicate
56899
straight edge
measurement
Cylinder Head
Camshaft Bore Inside Diameter “a” 37.000 - 37.025 mm
(1.4567 - 1.4577 in.)
a
a
a

56900

Valve/Valve Seat/Valve Guides:

Valve Clearance (cold)
Intake 0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust 0.25 - 0.35 mm (0.010 - 0.014 in.)
Valve Dimensions:
“A” Head Diameter
Intake 31.9 - 32.1 mm (1.256 - 1.264 in.)
Exhaust 25.9 - 26.1 mm (1.020 - 1.028 in.)
“B” Face Width
Intake 2.00 - 3.14 mm (0.079 - 0.124 in.)
Exhaust 2.00 - 3.14 mm (0.079 - 0.124 in.)
“C” Seat Width
Intake 0.9 - 1.1 mm (0.035 - 0.043 in.)
Exhaust 0.9 - 1.1 mm (0.035 - 0.043 in.)
“D” Margin Thickness
Valves Intake 0.5 - 0.9 mm (0.020 - 0.035 in.)
Exhaust 0.5 - 0.9 mm (0.020 - 0.035 in.)
Stem Outside Diameter
Intake 5.475 - 5.490 mm (0.2156 - 0.2161 in.)
Exhaust 5.460 - 5.475 mm (0.2150 - 0.2156 in.)
Guide Inside Diameter
Intake 5.500 - 5.512 mm (0.2165 - 0.2170 in.)
Exhaust 5.500 - 5.512 mm (0.2165 - 0.2170 in.)
Stem To Guide Clearance
Intake 0.010 - 0.037 mm (0.0004 - 0.0015 in.)
Exhaust 0.025 - 0.052 mm (0.0010 - 0.0020 in.)
Stem Run-out Limit (max.) 0.016 mm (0.0006 in.)

Page 1A-6 90-883064R02 JULY 2006

 Specifications

Valve Dimensions

“C”
“B”
“D”
“A”
Head Diameter Face Width Seat Width Margin Thickness

15.971 - 15.991 mm
Rocker Shaft Outside Diameter
(0.6288 - 0.6296 in.)
16.000 - 16.018 mm
Rocker Arm Inside Diameter of Bore
(0.6299 - 0.6306 in.)
Valve Opening Temperature 48° C - 51° C (118° F - 123° F)
Thermostat
Full Open Temperature 63° C (145° F)
Pump Type Trochoid
Engine Oil Pressure (Warm Engine)
@ 3000 RPM 207-278 kPa (30-40 psi)
Engine Oil Pan Capacity Either 3 quarts or 3 liters
Oil Pump:
Outer Rotor to Housing “a” 0.11 - 0.23 mm (0.0045 - 0.009 in.)
Inner Rotor to Outer Rotor “b” 0.12 mm (0.005 in.)
Rotor to Housing “c” 0.04 - 0.08 mm (0.0015 - 0.003 in.)
Oil Pressure Alarm Activates @ 15.51 kPa ± 5.17 (2.25 psi ± 0.75)
Lubrication
System a
bb

c
Transom Height:
Long Shaft 51 cm (20 in.)
Steering Pivot Range:
Tiller 90°
Mid-Section
Remote 60°
Tilt Pin Positions 5 + Shallow Water
Full Tilt Up Angle 69°
Allowable Transom Thickness 69.8 mm (2-3/4 in.)

90-883064R02 JULY 2006 Page 1A-7

Specifications

Gear Ratio 2.00:1

Gearcase Capacity 440 ml (14.9 fl. oz.)
Lubricant Type Premium Gear Lubricant

Forward Gear
Number of Teeth 26 Spiral/Bevel
Pinion Gear
Number of Teeth 13 Spiral/Bevel
Gear Housing
Pinion Height 0.64 mm (0.025 in.)
(2.00:1)
Forward Gear Backlash
Short Model No Adjustment
Long Model 0.28 -- 0.43 mm (0.11 -- .017 in.)
Water Pressure (Warm Engine)
@ 800 RPM 14 - 28 kPa (2 - 4 psi)
@ 6000 RPM (WOT) 69 - 103 kPa (12 - 17 psi)
Leak Test Pressure 68 - 83 kPa (10 - 12 psi)
for 5 Minutes
Gear Ratio 2.31:1
Gearcase Capacity 710 ml (24 fl. oz.)
Lubricant Type Premium Gear Lubricant

Forward Gear
Number of Teeth 30 Spiral/Bevel
Pinion Gear
Number of Teeth 13 Spiral/Bevel
Pinion Height 0.64 mm (0.025 in.)
Gear Housing Pinion Gear Locating Tool 91-12349A2
Bigfoot Flat Number #8
(2.3:1) Disc Number #3
Forward Gear Backlash 0.30 - 0.48 mm (0.012 - 0.019 in.)
Backlash Indicating Tool 91-78473
Mark Number #4
Water Pressure
@ 800 RPM (Idle) 14 - 41 kPa (2 - 6 psi)
@ 6000 RPM (WOT) 83 - 172 kPa (12 - 25 psi)
Leak Test Pressure 69 - 83 kPa (10 - 12 psi)
for 5 Minutes

Page 1A-8 90-883064R02 JULY 2006

 Specifications

Propeller Information Charts

Mercury/Mariner 30 EFI (4-Stroke) 2.00:1 Non-Bigfoot

Wide Open Throttle RPM : 5500 - 6000
Recommended Transom Heights : 38.1 cm (15 in.), 50.8 cm (20 in.), 57.2 cm (22.5 in.)
Right Hand Rotation Standard
Gear Reduction : 2.00:1

Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. Length Part Number
10” 19” 3 Aluminum Up to 272 kg Up to 4.3 m 72 - 85 km/h 48-73146A40
(600 lb.) (14 ft.) (45 - 53 MPH)
10” 17” 3 Aluminum Up to 318 kg Up to 4.3 m 63 - 74 km/h 48-73144A40
(700 lb.) (14 ft.) (39 - 46 MPH)
10” 16” 3 Steel 272 - 363 kg Up to 4.3 m 58 - 68 km/h 48-91818A5
(600 - 800 lb.) (14 ft.) (36 - 42 MPH)
10” 16” 3 Aluminum 272 - 363 kg Up to 4.3 m 58 - 68 km/h 48-73142A40
(600 - 800 lb.) (14 ft.) (36 - 42 MPH)
10-1/8” 15” 3 Steel 318 - 408 kg 4 - 4.3 m 53 - 63 km/h 48-855862A5
(700 - 900 lb.) (13 - 14 ft.) (33 - 39 MPH)
10-1/8” 15” 3 Aluminum 318 - 408 kg 4 - 4.3 m 53 - 63 km/h 48-73140A40
(700 - 900 lb.) (13 - 14 ft.) (33 - 39 MPH)
10-1/4” 14” 3 Steel 363 - 454 kg 4.3 - 4.6 m 48 - 58 km/h 48-855860A5
(800 - 1000 lb.) (14 - 15 ft.) (30 - 36 MPH)
10-1/4” 14” 3 Aluminum 363 - 454 kg 4.3 - 4.6 m 48 - 58 km/h 48-73138A40
(800 - 1000 lb.) (14 - 15 ft.) (30 - 36 MPH)
10-3/8” 13” 3 Steel 408 - 499 kg 4.3 - 4.9 m 43 - 53 km/h 48-855858A5
(900 - 1100 lb.) (14 - 16 ft.) (27 - 33 MPH)
10-3/8” 13” 3 Aluminum 408 - 499 kg 4.3 - 4.9 m 43 - 53 km/h 48-73136A40
(900 - 1100 lb.) (14 - 16 ft.) (27 - 33 MPH)
10-5/8” 12” 3 Steel 454 - 544 kg 4.6 - 5.2 m 39 - 47 km/h 48-855856A5
(1000 - 1200 lb.) (15 - 17 ft.) (24 - 29 MPH)
10-5/8” 12” 3 Aluminum 454 - 544 kg 4.6 - 5.2 m 39 - 47 km/h 48-73134A40
(1000 - 1200 lb.) (15 - 17 ft.) (24 - 29 MPH)
11-5/8” 11” 3 Steel 499 - 635 kg 4.6 - 5.2 m 34 - 42 km/h 48-823478A5
(1100 - 1400 lb.) (15 - 17 ft.) (21 - 26 MPH)
10-7/8” 11” 3 Aluminum 499 - 635 kg 4.6 - 5.2 m 34 - 42 km/h 48-85632A40
(1100 - 1400 lb.) (15 - 17 ft.) (21 - 26 MPH)
11-5/8” 10-1/2” 3 Aluminum 589 - 771 kg 4.6 - 5.5 m 31 - 39 km/h 48-827312A11
(1300 - 1700 lb.) (15 - 18 ft.) (19 - 24 MPH)
11-1/4” 10” 3 Aluminum 635 - 861 kg 4.9+ m 29 - 35 km/h 48-73132A40
(1400 - 1900 lb.) (16+ ft.) (18 - 22 MPH)
12-1/4” 9” 3 Steel 907 kg Pontoon 24 - 31 km/h 48-97868A10
(2000+ lb.) (15 - 19 MPH)
12-1/4” 9” 3 Aluminum 907 kg Pontoon 24 - 31 km/h 48-87818A11
(2000+ lb.) (15 - 19 MPH)
12-1/2” 8” 3 Aluminum 1088 kg Pontoon/House- 2 - 27 km/h 48-42738A11
(2400+ lb.) boat (1 - 17 MPH)
12-1/2” 8” Cup 3 Aluminum Pontoon 48-42738A13

90-883064R02 JULY 2006 Page 1A-9

Specifications

Mercury/Mariner 40 EFI (4-Stroke) 2.00:1 Non-Bigfoot

Wide Open Throttle RPM : 5500 - 6000
Recommended Transom Heights : 38.1 cm (15 in.), 50.8 cm (20 in.), 57.2 cm (22.5 in.)
Right Hand Rotation Standard
Gear Reduction : 2.00:1

Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length Part Number
10” 19” 3 Aluminum Up to 363 kg Up to 4.3 m 72 - 85 km/h 48-73146A40
(800 lb.) (14 ft.) (45 - 53 MPH)
10” 17” 3 Aluminum Up to 454 kg Up to 4.6 m 63 - 74 km/h 48-73144A40
(1000 lb.) (15 ft.) (39 - 46 MPH)
10” 16” 3 Steel 408 - 499 kg Up to 4.6 m 58 - 68 km/h 48-91818A5
(900 - 1100 lb.) (15 ft.) (36 - 42 MPH)
10” 16” 3 Aluminum 408 - 499 kg Up to 4.6 m 58 - 68 km/h 48-73142A40
(900 - 1100 lb.) (15 ft.) (36 - 42 MPH)
10-1/8” 15” 3 Steel 454 - 544 kg 4 - 4.6 m 53 - 63 km/h 48-855862A5
(1000 - 1200 lb.) (13 - 15 ft.) (33 - 39 MPH)
10-1/8” 15” 3 Aluminum 499 - 544 kg 4 - 4.6 m 53 - 63 km/h 48-73140A40
(1000 - 1200 lb.) (13 - 15 ft.) (33 - 39 MPH)
10-1/4” 14” 3 Steel 499 - 589 kg 4.3 - 4.9 m 48 - 58 km/h 48-855860A5
(1100 - 1300 lb.) (14 - 16 ft.) (30 - 36 MPH)
10-1/4” 14” 3 Aluminum 499 - 589 kg 4.3 - 4.9 m 48 - 58 km/h 48-73138A40
(1100 - 1300 lb.) (14 - 16 ft.) (30 - 36 MPH)
10-3/8” 13” 3 Steel 544 - 680 kg 4.3 - 5.2 m 43 - 53 km/h 48-855858A5
(1200 - 1500 lb.) (14 - 17 ft.) (27 - 33 MPH)
10-3/8” 13” 3 Aluminum 544 - 680 kg 4.3 - 5.2 m 43 - 53 km/h 48-73136A40
(1200 - 1500 lb.) (14 - 17 ft.) (27 - 33 MPH)
10-5/8” 12” 3 Steel 635 - 771 kg 4.6 - 5.2 m 39 - 47 km/h 48-855856A5
(1400 - 1700 lb.) (15 - 17 ft.) (24 - 29 MPH)
10-5/8” 12” 3 Aluminum 635 - 771 kg 4.6 - 5.2 m 39 - 47 km/h 48-73134A40
(1400 - 1700 lb.) (15 - 17 ft.) (24 - 29 MPH)
11-5/8” 11” 3 Steel 725 - 907 kg 4.9 - 5.5 m 34 - 42 km/h 48-823478A5
(1600 - 2000 lb.) (16 - 18 ft.) (21 - 26 MPH)
10-7/8” 11” 3 Aluminum 725 - 907 kg 4.9 - 5.5 m 34 - 42 km/h 48-85632A40
(1600 - 2000 lb.) (16 - 18 ft.) (21 - 26 MPH)
11-5/8” 10-1/2” 3 Aluminum 816 - 1088 kg 4.9+ m 31 - 39 km/h 48-827312A11
(1800 - 2400 lb.) (16+ ft.) (19 - 24 MPH)
11-1/4” 10” 3 Aluminum 907 - 1179 kg 5.2+ m 29 - 35 km/h 48-73132A40
(2000 - 2600 lb.) (17+ ft.) (18 - 22 MPH)
12-1/4” 9” 3 Steel 1043+ kg Pontoon 24 - 31 km/h 48-97868A10
(2300+ lb.) (15 - 19 MPH)
12-1/4” 9” 3 Aluminum 1043+ kg Pontoon 24 - 31 km/h 48-87818A11
(2300+ lb.) (15 - 19 MPH)
12-1/2” 8” 3 Aluminum 1225+ kg Pontoon/House- 2 - 27 km/h 48-42738A10
(2700+ lb.) boat (1 - 17 MPH)
12-1/2” 8” Cup 3 Aluminum Pontoon 48-42738A13

Page 1A-10 90-883064R02 JULY 2006

 Specifications

Mercury/Mariner 40 EFI (4-Stroke) 2.3:1 Bigfoot

Special soft rubber hub propellers designed to reduce clutch rattle
Wide Open Throttle RPM : 5500 - 6000
Recommended Transom Heights : 50.8 cm (20 in.) 63.5 cm (25 in.)
Right Hand Rotation Standard
Gear Reduction : 2.31:1

IMPORTANT: These specially designed rubber hub propellers are rated for 60 horsepower MAXIMUM.

Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. Length Part Number
13-3/4” 15” 3 Aluminum 544 - 680 kg 4.3 - 4.9 m 43 - 51 km/h 48-77342A33
(1200 - 1500 lb.) (14 - 16 ft.) (27 - 32 MPH)
14” 13” 3 Aluminum 680 - 907 kg 4.9 - 5.5m 35 - 43 km/h 48-77340A33
(1500 - 2000 lb.) (16 - 18 ft.) (22 - 27 MPH)
14” 11” 3 Aluminum 907 - 1361 kg Pontoon 27 - 34 km/h 48-77338A33
(2000 - 3000 lb.) (17 - 21 MPH)
14” 10” 3 Aluminum 1133+ kg Pontoon/Work 23 - 31 km/h 48-854342A33
(2500+ lb.) (14 - 19 MPH)
14” 9” 3 Aluminum 1587+ kg Houseboat/Work 2 - 24 km/h 48-854340A33
(3500+ lb.) (1 - 15 MPH)

90-883064R02 JULY 2006 Page 1A-11

Specifications

Torque Chart
Diameter x
Fastener Location Torque
Length (mm)
Nm lb. in. lb. ft.
Ignition
Coil Mounting Nuts M5 3.5 30
Coil Mount Plate Screw (Rear) M6 x 25 7 60
Coil Mount Plate Screw M6 x 30 8.5 75
Coil Plate Ground Screw M6 x 10 7 60
Spark Plug 12 mm 17 150
Charging & Starting System
Flywheel Cover Screws M6 x 25 8.5 75
Flywheel Nut N/A 157 116
Stator Screws M5 x 30 9.5 85
Voltage Regulator Screws M6 x 40 8.5 75
Starter Motor Mount Bolts M8 x 45 29.5 21.5
Starter Cable Nut 1/4-20 7 60
Starter Motor Thru-Bolts N/A 8 70
Battery Cable (+) Nut M6 7 60
Solenoid Plate Screw M6 x 14 5 45
Harness Retainer Screws M6 x 14 5 45
Wire Clamp Screw (Top of Block) M5 x 12 5 45

Page 1A-12 90-883064R02 JULY 2006

 Specifications

Diameter x
Fastener Location Torque
Length (mm)
Nm lb. in. lb. ft.
Electronic Fuel Injection
Intake Manifold Screws M6 x 25 8.5 75
Intake Manifold Screws M6 x 30 8.5 75
IAC Mount Screw N/A Drive Tight
IAC Nut M6 8.5 75
Fuel Distribution Manifold Screws N/A 3.5 31
Fuel Injector Screws N/A 3.5 31
Throttle Body Screws N/A 3.5 31
TPI Screws N/A 2 18
MAT Sensor N/A 1.5 12.5
MAP Sensor Mount Screw 10-16 x 5/8 in. Drive Tight
ECT Sensor N/A 1.5 15
ECM Mount Screws M6 x 25 5 45
Ground Screw (ECM Plate) M6 x 14 5 45
Brace Screw (ECM Plate) M6 x 16 8.5 75
CPS Mount Screws M5 x 16 5 45
VST Mounting Screws M6 x 25 5 45
VST Cover Screws M4 x 20 3.5 32
VST Drain Screw N/A 5.6 - 50 - 100
11.3
Fuel Pressure Regulator Screws M4 x 6 2.5 22
Fuel Baffle Screw M4 x 6 2.5 22
Float Shaft Screw M4 x 6 2.5 22
Fuel Cooler Screw M6 x 25 16 140
Fuel Filter Mount Screws M6 x 20 8 70
Fuel Filter Nut M6 5 45
Fuel Pump Mounting Screws M6 x 30 8.5 75
Fuel Pump Cover Screws M5 x 40 3.5 30
Cylinder Head
Cylinder Head Bolts M9 x 95 47 34.5
Cylinder Head Bolts M6 x 25 12 106
Baffle Plate Screws M4 x 10 Drive Tight
Valve Cover Screws M6 x 20 8 70
Valve Adjusting Nuts M6 13.5 120
Rocker Arm Shaft Screws M8 x 23 18 160 13
Driven Gear Screw M10 x 40 38 28

90-883064R02 JULY 2006 Page 1A-13

Specifications

Diameter x
Fastener Location Torque
Length (mm)
Nm lb. in. lb. ft.
Cylinder Block/Crankcase
Crankcase Cover Bolts - Center (*) M8 x 82 30 22
Crankcase Cover Bolts - Outer (*) M6 x 35 12 106
Exhaust Cover Screws M6 x 35 12 106
Connecting Rod Bolts (*) Special 17 150
Oil Filter N/A 8 70
Oil Filter Nipple N/A 40 29.5
Powerhead Mounting Bolts M8 x 110 44.5 33
Lifting Eye Screw M8 x 35 39.5 29
Oil Pressure Switch N/A 8.5 75
Oil Galley Plug 1/8-27 Pipe Plug 9 80
Oil Galley Plug 3/4-14 Pipe Plug 40.5 30
Oil Galley Plug 1/2-14 Pipe Plug 40.5 30
Lubrication
Oil Pump Mounting Screws M6 x 40 8 70
Oil Pump Cover Screws M6 x 16 8 70
Mid-Section
Top Cowl Latch Screw/Nut M4 x 14 Drive Tight
Top Rear Cowl Latch Screw/Nut M6 x 16 10 90
Bottom Cowl Screws M6 x 30 7 60
Bottom Cowl Screws M6 x 60 7 60
Rear Cowl Latch Screw (Bottom) M6 x 16 7 60
Oil Drain Plug N/A 23.5 17.5
Gear Housing Mounting Stud M10 16 144 12
Adapter Plate Mounting Screw M8 x 45 44.5 33
Co-Pilot Plate Bolt (Shoulder) 1/4-20 x 0.68 8 70
Steering Bracket Bolts M10 x 30 44 32.5
Steering Link Rod Bolt Special 27 20
Steering Link Rod Nut 3/8-24 Torque to 13.5 Nm
(120 lb. in.)
then back off 1/4 turn
Upper Mount Bolts M6 x 20 14.5 130
Upper Mount Bolts M12 x 154 32.5 24
Upper Mount Nuts M12 32.5 24
Lower Mount Bolts M10 x 105 44 32.5
Lower Mount Nuts M12 44 32.5
Ground Screws 10-16 x 0.38 Drive Tight
Tilt Lever Bolt (Shoulder) 3/8-16 x 0.62 25 18
Tilt Stop Bolt M10 x 40
Tilt Tube Nut 3/4-14 Torque to 43.4 Nm
(32 lb. ft.)
then back off 1/4 turn
Anchor Bracket Screws M8 x 30 34 25

Page 1A-14 90-883064R02 JULY 2006

 Specifications

Diameter x
Fastener Location Torque
Length (mm)
Nm lb. in. lb. ft.
Mid-Section - Continued
Anchor Bracket Screws M8 x 35 34 25
Anode Screws M6 x 25 7 60
Adapter Plate (Socket Head) Screw M6 x 55 17 150
Oil Pressure Relief Valve N/A 46 34
Oil Pickup/Gasket Screw M6 x 20 8.5 75
Oil Gallery Plug 1/2-14 Pipe Plug 33 24
Power Trim
Shock Rod Piston N/A 122 90
Piston Spring Plate Screws N/A 4 35
Cylinder End Cap N/A 61 45
Trim Cylinder/Reservoir Screws N/A 11 100
Pump to Manifold Screws N/A 8 70
Check Valve Plug N/A 13 120
Reservoir Screws N/A 9 80
Manual Tilt Assist
Plug, Velocity Valve N/A 8.5 75
Plug, Plunger (2) N/A 8.5 75
Shock Rod Piston N/A 122 90
Piston Spring Plate Screws N/A 4 35
Cylinder End Cap N/A 61 45
Tilt Cylinder/Reservoir Screws N/A 11 100
Accumulator N/A 47 35
Non-Bigfoot Gear Housing
Pinion Nut N/A 68 50
Bearing Carrier Screws M8 x 25 25.5 19
Vent, Fill/Drain Screw NA 7 60
Water Pump Cover Screws M6 x 16 7 60
Gear Housing Mounting Screws M10 x 45 54 40
Gear Housing Mounting Nut M10 54 40
Trim Tab Screw M8 x 20 31.5 23
Propeller Nut N/A 74.5 55

90-883064R02 JULY 2006 Page 1A-15

Specifications

Diameter x
Fastener Location Torque
Length (mm)
Nm lb. in. lb. ft.
Bigfoot Gear Housing
Bearing Carrier Nut M8 34 25
Water Pump Base Screws M6 x 25 7 60
Water Pump Cover Screws M6 x 30 7 60
Vent, Fill/Drain, Oil Level Screw N/A 7 60
Gear Housing Mounting Bolts M10 x 45 54 40
Gear Housing Mounting Nut M10 54 40
Trim Tab Screw 7/16 x 1-1/4 in. 30 22
Anode Screw M6 x 40 7 60
Propeller Nut
Throttle/Shift Linkage
Throttle/Shift Lever Screw M8 x 70 11.5 100
Throttle Cam Mounting Screw M6 x 40 8.5 75
Throttle Cam Screw 10-16 x 5/8 in. Drive Tight
Remote Control Cable Anchor Bracket Screws M6 x 16 8.5 75
Shift Spring Screw M5 x 16 5 45
Neutral Start Switch Screws M3 x 20 2.5 20
Shift Link Nut (Bigfoot) M6
Tiller Handle
Tiller Mounting Bracket Screws M10 x 90 47.5 35
Shift Handle Screw M8 x 150 11 100
Tiller Tube Retainer Screw M5 x 16 4 35
Tiller Mount Cover Screws M8 x 25 15 135
Pulley Case Screws Self-Tapping 10-16 x 1/2 2.5 20

Page 1A-16 90-883064R02 JULY 2006

 Maintenance

Important Information 1
Section 1B - Maintenance B

Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12
Inspection And Maintenance Schedule . . . . 1B-3 Fuel Line Inspection . . . . . . . . . . . . . . . . . 1B-12
Before Each Use . . . . . . . . . . . . . . . . . . . . 1B-3 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . 1B-13
After Each Use . . . . . . . . . . . . . . . . . . . . . . 1B-3 Oil Changing Procedure . . . . . . . . . . . . . . 1B-13
Every 100 Hours of Use or Once yearly, Changing Oil Filter . . . . . . . . . . . . . . . . . . . 1B-14
Whichever occurs first . . . . . . . . . . . . . . . . 1B-3 Checking and Adding Engine Oil . . . . . . . 1B-14
Every 300 Hours of Use or Three Years 1B-4 Changing Gearcase Lubricant . . . . . . . . . . . . 1B-15
Before Periods of Storage . . . . . . . . . . . . 1B-4 83 mm (3-1/4 in.) Diameter Gearcase . . 1B-15
Flushing the Cooling System . . . . . . . . . . . . . 1B-4 108 mm (4-1/4 in.) Diameter Gearcase . 1B-16
Steering Link Rod Fasteners . . . . . . . . . . . . . 1B-5 Storage Preparation . . . . . . . . . . . . . . . . . . . . 1B-18
Corrosion Control Anode . . . . . . . . . . . . . . . . 1B-6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . 1B-18
Spark Plug Inspection and Replacement . . . 1B-7 Protecting External Outboard
Battery Inspection . . . . . . . . . . . . . . . . . . . . . . 1B-7 Components . . . . . . . . . . . . . . . . . . . . . . . . 1B-18
Fuse Replacement - Electric Start Models . 1B-8 Protecting Internal Engine Components 1B-18
Timing Belt Inspection . . . . . . . . . . . . . . . . . . . 1B-9 Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-19
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . 1B-9 Positioning Outboard for Storage . . . . . . 1B-19
Checking Power Trim Fluid . . . . . . . . . . . . . . 1B-11 Battery Storage . . . . . . . . . . . . . . . . . . . . . 1B-19
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12

90-883064R02 JULY 2006 Page 1B-1

Maintenance

Special Tools
1. Crankcase Oil Pump P/N 90265A5

2. Oil Filter Wrench P/N 91-802653Q2

3. Flushing Attachment P/N 44357Q2

Page 1B-2 90-883064R02 JULY 2006

 Maintenance

Inspection And Maintenance Schedule

To keep your outboard in the best operating condition, it is important that your outboard
receive the periodic inspections and maintenance listed in the Inspection and Maintenance
Schedule. We urge you to keep it maintained properly to ensure the safety of you and your
passengers and retain its dependability.

WARNING
Neglected inspection and maintenance service of your outboard or attempting to
perform maintenance or repair on your outboard if you are not familiar with the
correct service and safety procedures could cause personal injury, death, or
product failure.
Before Each Use
1. Check engine oil level.
2. Check that lanyard stop switch stops the engine.
3. Visually inspect the fuel system for deterioration or leaks.
4. Check outboard for tightness on transom.
5. Check steering system for binding or loose components.
6. Visually check steering link rod fasteners for proper tightness.
7. Check propeller blades for damage.
After Each Use
1. Flush out the outboard cooling system if operating in salt or polluted water.
2. If operating in salt water, wash off all salt deposits and flush out the exhaust outlet of the
propeller and gearcase with fresh water.
Every 100 Hours of Use or Once yearly, Whichever occurs first
1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.
2. Change engine oil and replace the oil filter. The oil should be changed more often when
the engine is operated under adverse conditions such as extended trolling.
3. Inspect thermostat visually for corrosion, broken spring, and to determine that the valve
is completely closed at room temperature. If questionable, inspect thermostat. Refer to
Section 4B - Thermostat.
4. Inspect and clean spark plugs.
5. Check engine fuel filter for contaminants.
6. Check engine timing setup.
7. Check corrosion control anodes. Check more frequently when used in salt water.
8. Drain and replace gearcase lubricant.
9. Lubricate splines on the driveshaft.
10. Check and adjust valve clearance, if necessary.
11. Check power trim fluid.
12. Inspect battery.
13. Check control cable adjustments.
14. Inspect timing belt.

90-883064R02 JULY 2006 Page 1B-3

Maintenance

15. Remove engine deposits with Power Tune Engine Cleaner.

16. Check tightness of bolts, nuts, and other fasteners.
Every 300 Hours of Use or Three Years
1. Replace water pump impeller, more often if overheating occurs or reduced water
pressure is noted.
Before Periods of Storage
1. Refer to Storage in this section.

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.
IMPORTANT: The engine must be run during flushing in order to open the thermostat
and circulate water through all water passages.
NOTE: You can have the outboard tilted or in the vertical operating position during flushing.

WARNING
To avoid possible injury when flushing, remove the propeller.
1. Place the outboard in either the vertical operating position or in a tilted position.
2. Remove propeller. Refer to Section 1C - Propeller Replacement.
3. Thread a water hose into the rear fitting. Partially open the water tap (1/2 maximum).
Do not open the water tap all the way, as this allows a high pressure flow of water.

a - Water hose threaded into rear fitting

IMPORTANT: Do not run engine above idle when flushing.

4. Shift outboard into neutral. Start the engine and flush the cooling system for at least five
minutes. Keep engine speed at idle.
5. Stop the engine. Turn off the water and remove hose. Reinstall the propeller.

Page 1B-4 90-883064R02 JULY 2006

 Maintenance

Steering Link Rod Fasteners

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.
IMPORTANT: The steering link rod that connects the steering cable to the engine
must be fastened using special washer head bolt (“a” - Part Number 10-823919) and
self-locking nylon insert locknuts (“b” & “c” - Part Number 11-826709113). 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.

b
f
d
e

a - Special washer head bolt (10-823919)

b - Nylon insert locknut (11-826709113)
c - Nylon insert locknut (11-826709113)
d - Flat washers
e - Spacer (12-71970)
f - Link rod mount hole

1. Assemble steering link rod to steering cable with two flat washers and nylon insert
locknut (b). Tighten locknut (c) until it seats, then back nut off 1/4 turn.
2. Assemble steering link rod to engine with special washer head bolt, locknut (b) and
spacer. First torque bolt (a) to 27 Nm (20 lb. ft.), then torque locknut (b) to 27 Nm
(20 lb. ft.).

Description Nm lb. in. lb. ft.

Special washer head bolt 27 20
Nylon insert locknut 27 20

90-883064R02 JULY 2006 Page 1B-5

Maintenance

Corrosion Control Anode

Your outboard has control anodes at different locations. An anode helps protect the
outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of
the outboard metals.
Each 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.
1. The gearcase has two corrosion control anodes. Another anode is installed on the
bottom of the transom bracket assembly.
c

a
a - Bottom anode
b - Trim tab
c - Side anodes (Bigfoot models only)

Page 1B-6 90-883064R02 JULY 2006

 Maintenance

Spark Plug Inspection and Replacement

Inspect spark plugs at the recommended intervals.

WARNING
Avoid serious injury or death from fire or explosion caused by damaged spark plug
boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel vapors
under the engine cowl. To avoid damaging spark plug boots, do not use any sharp
object or metal tool such as pliers, screwdriver, etc. to remove spark plug boots.
1. Remove the spark plug leads by twisting the rubber boots slightly and pulling 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. Refer to Section 1A - Specifications.

Spark plug gap
Spark plug 1.0 mm (0.040 in.)
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 specifications.
Description Nm lb. in. lb. ft.
Spark plug 17 12.5

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.

90-883064R02 JULY 2006 Page 1B-7

Maintenance

Fuse Replacement - Electric Start Models

IMPORTANT: Always carry spare 20 ampere fuses.
The electrical wiring circuits on the outboard are protected from overload by fuses in the
wiring. If the fuse is blown, try to locate and correct the cause of the overload. If the cause
is not found, the fuse may blow again.
1. Open the fuse holder and look at the silver colored band inside the fuse. If band is broken
replace the fuse. Replace fuse with a new fuse with the same amperage rating.

a c

15

b d

58858

f
a - SmartCraft data bus circuit - 5 ampere fuse
b - Fuel pump/idle air control/fuel injector circuits - 20 ampere fuse
c - Main relay/accessories - 20 ampere fuse
d - Ignition coil circuit - 25 ampere fuse
e - Spare 20 ampere fuse
f - Broken fuse band

Page 1B-8 90-883064R02 JULY 2006

 Maintenance

Timing Belt Inspection

1. Inspect the timing belt and replace if any of the following conditions are found.
a. Cracks in the back of the belt or in the base of the belt teeth.
b. Excessive wear at the roots of the cogs.
c. Rubber portion swollen by oil.
d. Belt surfaces roughened.
e. Signs of wear on edges or outer surfaces of belt.

a - Timing belt

Lubrication Points
Lubricate Point 1 with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon.
1. Propeller Shaft - Refer to Section 1C - Propeller Replacement for removal and instal-
lation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propel-
ler hub from corroding and seizing to the shaft.

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

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

90-883064R02 JULY 2006 Page 1B-9

Maintenance

Lubricate Points 2 through 6 with 2-4-C Marine Lubricant with Teflon or Special
Lubricant 101.
2. Swivel Bracket - Lubricate through fitting.
3. Tilt Support Lever - Lubricate through fitting.
4. Tilt Tube - Lubricate through fitting.

2 4

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

34 Special Lubricant 101 92-802865A1 92-802865Q1

5. Steering Cable Grease Fitting (If equipped) - Rotate steering wheel to fully retract the
steering cable end into the outboard tilt tube. Lubricate through fitting.
Lubricate Pivot Points with light weight oil.
6. This grease fitting is for lubricating the threaded rod for the co-pilot.
6

a
5

b
a - Steering cable end
b - Pivot points
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

Page 1B-10 90-883064R02 JULY 2006

 Maintenance

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. A hydraulically locked
steering cable will cause loss of steering control, possibly resulting in serious
injury or death.

Checking Power Trim Fluid

1. Tilt outboard to the full up position and engage the tilt support lock.

a - Tilt support lock

2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of
the fill hole. Add Power Trim & Steering Fluid. If not available, use automotive automatic
transmission fluid (ATF).

a - Fill cap
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
Power Trim and Steering
114 92-802880A1 92-802880Q1
Fluid

90-883064R02 JULY 2006 Page 1B-11

Maintenance

Fuel System
WARNING
Avoid serious injury or death from gasoline fire or explosion. Carefully follow all
fuel system service instructions. Always stop the engine. 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 signs of fuel leakage.
Fuel Filter
IMPORTANT: Visually inspect for fuel leakage from the filter by squeezing the primer
bulb until firm, forcing fuel into the filter.
Check the fuel filter for water accumulation or sediment. If water is in the fuel, remove the
sight bowl and drain the water. If the filter appears to be contaminated, remove and replace.

b
58859

a - Cover
b - Sight bowl
c - Filter element
d - O-ring
REMOVAL
1. Read fuel system servicing information and warning.
2. Pull out the filter assembly from mount. Hold onto the cover to prevent it from turning
and remove the sight bowl. Empty contents into an approved container.
3. Pull out the filter element and replace it if necessary.
INSTALLATION
1. Push the filter element into the cover.
2. Place the O-ring seal into its proper position on the sight bowl and screw the sight bowl
hand tight into the cover.
3. Push filter assembly back into mount.
Fuel Line Inspection
Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other
signs of deterioration or damage. If any of these conditions are found, the fuel line or primer
bulb must be replaced.

Page 1B-12 90-883064R02 JULY 2006

 Maintenance

Changing Engine Oil

Oil Changing Procedure
PUMP METHOD
1. Place the outboard in a vertical upright position.
2. Remove dipstick and slide adapter tube/pump down dipstick tube. Pump out the engine
oil into an appropriate container.
a

a - Crankcase oil pump

Crankcase Oil Pump 90265A5

DRAIN PLUG METHOD

1. Tilt the outboard up to the trailer position.
2. Turn the steering on the outboard so that the drain hole is facing downward. Remove
drain plug and drain engine oil into an appropriate container. Lubricate the seal on the
drain plug with oil and reinstall.

a - Drain hole
Tube Ref. Quicksilver Part
Description Mercury Part Number
No. Number

110 4-Stroke 10W-30 Outboard Oil 92-802833A1 92-802833Q1

90-883064R02 JULY 2006 Page 1B-13

Maintenance

Changing Oil Filter

1. Place a rag or towel below the oil filter to absorb any spilled oil.
2. Unscrew old filter by turning the filter counterclockwise.
3. Clean the mounting base. Apply film of clean oil to filter gasket. Do not use grease.
Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn.

a - Oil filter
b - Oil filter wrench
Oil Filter Wrench 91-802653Q02

Checking and Adding Engine Oil

IMPORTANT: Do not overfill. Be sure that the outboard is upright and not tilted when
checking oil.
Description
Engine Oil Capacity 3.0 liters (3 U.S. Quarts)

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
Mercury MerCruiser 4-cycle
79 92-802837A1 92-802837Q1
25W40 Engine Oil
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

1. Remove the oil fill cap and add oil to to proper operating level.
2. Idle engine for five minutes and check for leaks. Stop engine and check oil level on
dipstick. Oil must be between full mark and add mark. Add oil if necessary.

a
b
c

a - Dipstick
b - Oil fill cap
c - Full mark
d - Add mark

Page 1B-14 90-883064R02 JULY 2006

 Maintenance

Changing Gearcase Lubricant

83 mm (3-1/4 in.) Diameter 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.
Examine the drained gearcase lubricant for metal particles. A small amount of 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.

DRAINING GEARCASE
1. Place outboard in a vertical operating position.
2. Place a drain pan below outboard.
3. Remove vent plugs and fill/drain plug and drain lubricant.

a - Fill/drain plug
b - Vent plug

CHECKING GEARCASE LUBRICANT LEVEL AND REFILLING GEARCASE

d
b

a - Vent plug
b - Lubricant tube
c - Vent plug opening
d - Fill plug and washer

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

Lubricant
Gearcase lubricant capacity 440 ml (14.9 fl. oz.)

90-883064R02 JULY 2006 Page 1B-15

Maintenance

1. Place outboard in a vertical operating position.

2. Remove vent plug.
3. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole.
IMPORTANT: Replace sealing washers if damaged.
4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubri-
cant tube.
5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.

108 mm (4-1/4 in.) Diameter 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.

DRAINING GEARCASE
1. Place outboard in a vertical operating position.
2. Place a drain pan below outboard.
3. Remove vent plugs and fill/drain plug and drain lubricant.

c
b
a

a - Fill/drain plug
b - Rear vent plug
c - Front vent plug

Page 1B-16 90-883064R02 JULY 2006

 Maintenance

CHECKING LUBRICANT LEVEL AND FILLING GEARCASE

1. Place outboard in a vertical operating position.
2. Remove the front vent plug and rear vent plug.
3. Place lubricant tube into the fill hole and add lubricant until it appears at the front vent
hole. At this time install the front vent plug and sealing washer.
4. Continue adding lubricant until it appears at the rear vent hole.
5. Stop adding lubricant. Install the rear vent plug and sealing washer before removing
lubricant tube.
6. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.

d
a

c b

a - Front vent plug

b - Rear vent plug
c - Front vent hole
d - Rear vent hole
e - Fill/drain plug and sealing washer
Lubricant
Gearcase lubricant capacity 710 ml (24 fl. oz.)

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

90-883064R02 JULY 2006 Page 1B-17

Maintenance

Storage Preparation
The major consideration in preparing your outboard for storage is to protect it from rust,
corrosion, and damage caused by freezing of trapped water.
The following storage procedures should be followed to prepare your outboard for
out-of-season storage and prolonged storage of two months or longer.

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.

Fuel System
IMPORTANT: Gasoline containing ethanol or methanol alcohol 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 pos-
sible from the fuel tank, remote fuel line, and engine fuel system.
Fill the fuel tank and engine fuel system with stabilized fuel to help prevent formation of
varnish and gum. Proceed with the following instructions.
1. Portable Fuel Tank - Pour the required amount of gasoline stabilizer (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 gasoline stabilizer (follow
instructions on container) into a separate container and mix with approximately one liter
(one quart) of gasoline. Pour this mixture into the fuel tank.
3. Remove the fuel filter sight bowl and empty contents in a suitable container. Add 3 cc
(1/2 teaspoon) of gasoline stabilizer into the fuel filter sight bowl and reinstall.
4. Place the outboard in water or connect flushing attachment for circulating cooling water.
Run the engine for 15 minutes to allow treated fuel to fill the engine fuel system.
Flushing Attachment 91-44357Q 2

Protecting External Outboard Components

1. Lubricate all outboard components. Refer to Inspection and Maintenance Schedule.
2. Touch up any paint nicks.
3. Spray Corrosion Guard on external metal surfaces. Do not spray Corrosion Guard on
corrosion control anodes.

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

120 Corrosion Guard 92-802878-55 92-802878Q55

Protecting Internal Engine Components

1. Remove the spark plugs and inject a small amount of engine oil inside of each cylinder.
2. Rotate the flywheel manually several times to distribute the oil in the cylinders. Reinstall
spark plugs.
3. Change the engine oil. Refer to Changing Engine Oil.

Page 1B-18 90-883064R02 JULY 2006

 Maintenance

Gearcase
1. Drain and refill the gearcase lubricant. Refer to Changing Gearcase Lubricant.

Positioning Outboard for Storage

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

CAUTION
If outboard is stored tilted up in freezing temperature, trapped cooling water or rain
water that may have entered the propeller exhaust outlet in the gearcase could
freeze and cause damage to the outboard.

Battery Storage
1. Follow the battery manufacturer’s instructions for storage and recharging.
2. Remove the battery from the boat and check water level. Recharge if necessary.
3. Store the battery in a cool, dry place.
4. Periodically check the water level and recharge the battery during storage.

90-883064R02 JULY 2006 Page 1B-19

 General Information

Important Information 1
Section 1C - General Information C
Table of Contents
Serial Number Location . . . . . . . . . . . . . . . . . 1C-2 Model 30/40 EFI (4-Stroke) Powerhead
Conditions Affecting Performance . . . . . . . . 1C-2 Starboard View 2006 And Newer . . . . . . . . . 1C-14
Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2 Model 30/40 EFI (4-Stroke) Powerhead
Weight Distribution (Passengers and Gear) Port View 2006 And Newer . . . . . . . . . . . . . . 1C-15
Inside the Boat . . . . . . . . . . . . . . . . . . . . . 1C-3 Model 30/40 EFI (4-Stroke) Powerhead
Bottom of Boat . . . . . . . . . . . . . . . . . . . . . . 1C-4 Aft View 2006 And Newer . . . . . . . . . . . . . . . 1C-16
Water Absorption . . . . . . . . . . . . . . . . . . . . 1C-4 Propeller Selection . . . . . . . . . . . . . . . . . . . . . 1C-17
Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-4 Propeller Removal/Installation . . . . . . . . . . . . 1C-18
Engine Detonation . . . . . . . . . . . . . . . . . . . 1C-5 83 mm (3-1/4 in.) Diameter Gearcase . . 1C-18
Following Complete Submersion . . . . . . . . . 1C-6 108 mm (4-1/4 in.) Diameter Gearcase . 1C-19
Engine Submerged While Running Power Trim System . . . . . . . . . . . . . . . . . . . . . 1C-21
(Special Instructions) . . . . . . . . . . . . . . . . 1C-6 General Information . . . . . . . . . . . . . . . . . . 1C-21
Salt Water Submersion Power Trim Operation . . . . . . . . . . . . . . . . 1C-21
(Special Instructions) . . . . . . . . . . . . . . . . 1C-6 Trim In Angle Adjustment . . . . . . . . . . . . . 1C-22
Fresh Water Submersion Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . 1C-23
(Special Instructions) . . . . . . . . . . . . . . . . 1C-6 Compression Check . . . . . . . . . . . . . . . . . . . . 1C-23
Model 30/40 EFI (4-Stroke) Powerhead Cylinder Leakage Testing . . . . . . . . . . . . . . . . 1C-25
Front View 2005 And Prior . . . . . . . . . . . . . . 1C-8 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-25
Model 30/40 EFI (4-Stroke) Powerhead Water Pressure Measurement . . . . . . . . . . . . 1C-26
Starboard View 2005 And Prior . . . . . . . . . . 1C-9 Painting Procedures . . . . . . . . . . . . . . . . . . . . 1C-27
Model 30/40 EFI (4-Stroke) Powerhead Cleaning & Painting Aluminum Propellers & Gear
Port View 2005 And Prior . . . . . . . . . . . . . . . 1C-10 Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-27
Model 30/40 EFI (4-Stroke) Powerhead Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-27
Top View 2005 And Prior . . . . . . . . . . . . . . . . 1C-11 Gear Housings . . . . . . . . . . . . . . . . . . . . . . 1C-27
Model 30/40 EFI (4-Stroke) Powerhead Decal Removal/Application . . . . . . . . . . . . . . 1C-28
Aft View 2005 And Prior . . . . . . . . . . . . . . . . 1C-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-28
Model 30/40 EFI (4-Stroke) Powerhead Instructions for Wet Application . . . . . . . . 1C-28
Front View 2006 And Newer . . . . . . . . . . . . . 1C-13

90-883064R02 JULY 2006 Page 1C-1

General Information

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 top side of the swivel bracket.
a
OGXXXXXX
b
19XX
XXXX c

e
XX d
a - Serial number
b - Model year
c - Model description
d - Year manufactured
e - Certified Europe insignia

Conditions Affecting Performance

Weather

Rated hp

Horsepower Loss
Due to Atmosphere
Conditions
Summer hp
Secondary Loss Due to
Propeller Becoming To
Large for Summer
Horsepower

RPM Drop Due

to Weather

ENGINE RPM Rated RPM

It is a known fact that weather conditions exert a profound effect on the 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.

Page 1C-2 90-883064R02 JULY 2006

 General Information

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 a temperature of 25° C (77° F) 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 to 5 km/h (2 to 3 MPH) in some cases. Nothing will regain this speed for the
boater, but the coming of cool, dry weather.
Pointing out the consequences of weather effects, an engine running on a hot, humid day
may encounter a loss of as much as 14% of the horsepower it would produce on a dry, brisk
day. The horsepower that any internal combustion engine produces, depends upon the
density of the air that it consumes. The density of air is dependent upon the ambient air
temperature, the barometric pressure and the humidity (water vapor) 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 drop in available horsepower, this propeller will, in effect, become too large.
Consequently, the engine operates at less than its recommended RPM.
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 can
be regained by switching to a smaller pitch propeller that allows the engine to 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, the
engine will be operating in an RPM range that discourages damaging detonation. This
enhances overall reliability and durability of the engine.

Weight Distribution (Passengers and Gear) Inside the Boat

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.) At extremes, can cause the boat to porpoise.
(3.) Can make the bow bounce excessively in choppy water.
(4.) Increases the danger of waves splashing into the boat when coming off plane.
b. Shifting weight to the front (bow) and/or
c. Adjusting tilt pin to achieve best performance and handling.
(1.) Improves ease of planing.
(2.) Improves rough water ride.
(3.) At extremes, can make the boat veer back and forth (bow steer).

90-883064R02 JULY 2006 Page 1C-3

General Information

Bottom of Boat
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 thru-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.
Cavitation
Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle on
the gearcase, from an irregularity in the propeller blade itself or from too high engine
installation. 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 will occur.

Page 1C-4 90-883064R02 JULY 2006

 General Information

Engine Detonation
Detonation in a 4-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. These shock waves often
find or create a weakness: the dome of a piston, cylinder head or gasket, piston rings or
piston ring lands, piston pin and bearings.
A few of the most common causes of detonation in a marine 4-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 resulting in higher compression ratio.
Detonation usually can be prevented if:
• The engine is correctly set up.
• Diligent maintenance is applied to combat the detonation causes.

51115

a - Damaged piston from detonation

90-883064R02 JULY 2006 Page 1C-5

General Information

Following Complete Submersion

Engine Submerged While Running (Special Instructions)
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.
Salt Water Submersion (Special Instructions)
Due to the corrosive effect of salt water on internal engine components, complete
disassembly of the engine is necessary before any attempt is made to start the engine.
Fresh Water Submersion (Special Instructions)
1. Recover the 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 the powerhead. Most
water can be eliminated by placing the engine in a horizontal position with spark plug
holes down and rotating the flywheel.
5. Drain water from the fuel system as follows:
a. Disconnect remote fuel hose from engine.
b. Loosen drain screw of vapor separator and drain fuel/water into a suitable container.
Tighten drain screw after draining.

WARNING
Always release the fuel pressure in the high pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel may
spray out.
c. Release fuel pressure. Refer to Section 3C - Releasing Fuel Pressure in the High
Pressure Fuel Line. Remove high pressure fuel line from bottom of vapor separator
fuel cooler and drain fuel/water into a suitable container. Replace in-line fuel filter of
high pressure fuel line and reconnect fuel line to connection on fuel cooler.
d. Remove fuel distribution manifold and empty contents into a suitable container.
Inspect and clean fuel injectors. Reinstall fuel injectors/fuel distribution manifold.
e. Empty contents of water separating fuel filter into a suitable container.
6. Change engine oil and filter as outlined in Section 1B - Changing Engine Oil. Run the
outboard for a short time and check for presence of water in oil. If water is present (milky
appearance) drain and refill as previously mentioned.
7. Pour alcohol into the engine through the throttle body. Alcohol will absorb water. Again
rotate the flywheel.
8. Turn engine over and pour alcohol into the spark plug openings and rotate the flywheel.
9. Turn engine over with the spark plug openings down, remove the manifold plugs and pour
engine oil into the intake manifold plug holes while rotating the flywheel to distribute oil
throughout the crankcase.

Page 1C-6 90-883064R02 JULY 2006

 General Information

10. Again turn the engine over and pour approximately one teaspoon of engine oil into each
spark plug opening. Again rotate flywheel to distribute oil in the cylinders.
11. Remove and clean the intake manifold assembly and fuel pump assembly.
12. Dry all wiring and electrical components using compressed air.
13. Disassemble the engine starter motor and dry the brush contacts, armature and other
corrodible parts.
14. Reinstall spark plugs, intake manifold and fuel pump.
15. 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.
16. If engine fails to start, determine cause: fuel, electrical or mechanical. Engine should be
run within two 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.

90-883064R02 JULY 2006 Page 1C-7

General Information

Model 30/40 EFI (4-Stroke) Powerhead Front View 2005 And

Prior
b

m c

d
j

e
58858
g
f
a - Remote control and engine harness connection
b - DDT test port
c - Fuses (3-20 ampere, 1-15 ampere)
d - Positive (+) 12 volt battery connection
e - Fuel connection
f - Battery cables
g - Throttle and shift cables
h - Remote control harness
i - ECM
j - Throttle air by-pass hose
k - Intake manifold
l - Engine harness connections to ECM
m - 10 pin SmartCraft connection

Page 1C-8 90-883064R02 JULY 2006

 General Information

Model 30/40 EFI (4-Stroke) Powerhead Starboard View 2005

And Prior
b c
d

a e

o i
g

n
h

j
l k
58982

a - High pressure fuel line from VST

b - Lifting eye
c - Fuel distribution manifold
d - Engine harness connection to remote control harness
e - 10 pin SmartCraft connection
f - Intake manifold
g - Throttle air by-pass hose
h - Idle Air Control (IAC)
i - Fuel injectors
j - Shift arm
k - Shift linkage
l - Throttle linkage
m - Throttle lever
n - Throttle cam
o - Fuel filter

90-883064R02 JULY 2006 Page 1C-9

General Information

Model 30/40 EFI (4-Stroke) Powerhead Port View 2005 And

Prior

b
a
c d e

f
m

k
f
l

j i h g
58979

a - Starter motor g - Oil dipstick

b - Negative battery connection h - Engine Coolant Temperature
c - Access port - water pressure/ (ECT) sender
temperature sender accessory i - Oil filter
d - Thermostat housing j - Oil pressure port
e - Voltage regulator k - Vapor Separator Tank (VST)
f - Ignition coils l - Fuel cooler
m - Schrader test valve

Page 1C-10 90-883064R02 JULY 2006

 General Information

Model 30/40 EFI (4-Stroke) Powerhead Top View 2005 And

Prior

f
e 58976

a - Camshaft timing gear

b - Timing belt
c - Crank position sensor
d - Flywheel
e - Remote control and engine harness connection
f - 10 pin SmartCraft connection

90-883064R02 JULY 2006 Page 1C-11

General Information

Model 30/40 EFI (4-Stroke) Powerhead Aft View 2005 And

Prior

a
b

g
e

58974

a - Lifting eye
b - Valve cover
c - Crankcase breather hose
d - Oil fill plug
e - Fuel pump - water cooled
f - Main Power Relay (MPR)
g - Trim down relay
h - Trim up relay

Page 1C-12 90-883064R02 JULY 2006

 General Information

Model 30/40 EFI (4-Stroke) Powerhead Front View 2006 And

Newer

a - Battery cables
b - Fuel connection
c - Intake manifold
d - Diagnostic port
e - ECM
f - 14 pin engine harness connection
g - Flywheel cover
h - CAN 1 termination resistor
i - Fuses (1 5 ampere, 2-20 ampere, 1-25 ampere 1 spare 20 ampere)
j - Positive (+) 12 volt battery connection
k - Cowl trim switch connector

90-883064R02 JULY 2006 Page 1C-13

General Information

Model 30/40 EFI (4-Stroke) Powerhead Starboard View 2006

And Newer

a - Shift arm
b - Throttle linkage
c - Tell tale
d - Throttle lever
e - Throttle cam
f - Fuel filter
g - High pressure fuel line from VST
h - Lifting eye
i - Fuel distribution manifold
j - Intake manifold
k - CAN 1 termination resistor
l - 14 Pin harness connector
m - Diagnostic conector
n - Throttle air by-pass hose
o - Idle Air Control (IAC)
p - Fuel injectors

Page 1C-14 90-883064R02 JULY 2006

 General Information

Model 30/40 EFI (4-Stroke) Powerhead Port View 2006 And

Newer

a - Trim motor wires

b - Fuel cooler
c - Port cowl trim switch connector
d - Starter motor
e - Negative battery cable
f - 14 pin harness connector
g - CAN 1 termination resistor
h - VST
i - Thermostat housing
j - Voltage regulator
k - Ignition coils
l - Trim up relay
m - Trim down relay
n - Main power relay
o - Oil dip stick
p - Oil filter

90-883064R02 JULY 2006 Page 1C-15

General Information

Model 30/40 EFI (4-Stroke) Powerhead Aft View 2006 And

Newer

a - Tell tale
b - Main power relay
c - Trim down relay
d - Trim up relay
e - Lifting eye
f - Crankcase breather hose
g - Fuel filter
h - Oil fill plug
i - Fuel pump
j - Oil pump

Page 1C-16 90-883064R02 JULY 2006

 General Information

Propeller Selection
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 Accessories Guide for a complete list of available
propellers.
1. Select a propeller that will allow the engine to operate at or near the top of the
recommended full throttle RPM range 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.

90-883064R02 JULY 2006 Page 1C-17

General Information

Propeller Removal/Installation
83 mm (3-1/4 in.) Diameter Gearcase
WARNING
If the propeller shaft is rotated while the engine is in gear, there is the possibility that
the engine will crank over and start. To prevent this type of accidental engine
starting and possible serious injury caused from being struck by a rotating
propeller, always shift outboard to neutral position and remove spark plug leads
when servicing the propeller.
1. Shift outboard to neutral position.
2. Remove the spark plug leads to prevent engine from starting.

a
a - Propeller nut retainer tab

3. Straighten the bent tabs on the propeller nut retainer.

4. Place a block of wood between the gearcase and propeller to hold propeller and remove
propeller nut. Pull propeller straight off the shaft.
5. Coat the propeller shaft with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon.

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

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

IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller
shaft, especially in salt water, always apply a coat of the recommended lubricant to
the entire propeller shaft at the recommended maintenance intervals and also each
time the propeller is removed.
c
d

a
b
a - Forward thrust hub
b - Propeller
c - Propeller nut retainer
d - Propeller nut

Page 1C-18 90-883064R02 JULY 2006

 General Information

6. Flo-Torq I Drive Hub Propellers - Install forward thrust hub, propeller, propeller nut
retainer, and propeller nut onto the prop shaft.
7. Place propeller nut retainer over the pins. Place a block of wood between the gearcase
and propeller and tighten propeller nut to specification, aligning flat sides of the propeller
nut with tabs on the propeller nut retainer.

Description Nm lb. in. lb. ft.

Propeller nut 75 55

8. Secure propeller nut by bending tabs up and against the flats on the propeller nut.
9. Reinstall spark plug leads.

108 mm (4-1/4 in.) Diameter Gearcase

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

a - Propeller nut retainer tab

Description Nm lb. in. lb. ft.

Propeller nut 75 55

3. Straighten the bent tabs on the propeller nut retainer.

4. Place a block of wood between the gearcase and propeller to hold propeller and remove
propeller nut. Pull propeller straight off the shaft.
5. Coat the propeller shaft with Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon.

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

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

IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller
shaft, especially in salt water, always apply a coat of the recommended lubricant to
the entire propeller shaft at the recommended maintenance intervals, and also each
time the propeller is removed.

90-883064R02 JULY 2006 Page 1C-19

General Information

6. Flo-Torq I Drive Hub Propellers - Install thrust washer, propeller, continuity washer,
thrust hub, propeller nut retainer, and propeller nut onto the shaft.

e d

a
f c b
a - Thrust washer
b - Propeller
c - Continuity washer
d - Thrust hub
e - Propeller nut retainer
f - Propeller nut

7. Flo-Torq II Drive Hub Propellers - Install forward thrust hub, replaceable drive sleeve,
propeller, thrust hub, propeller nut retainer and propeller nut onto the shaft.

e c
f

d a
b
a - Forward thrust hub
b - Drive sleeve
c - Propeller
d - Thrust hub
e - Propeller nut retainer
f - Propeller nut

8. Place a block of wood between gearcase and propeller and torque propeller nut to
specification.

Description Nm lb. in. lb. ft.

Propeller nut 75 55

9. Secure propeller nut by bending three of the tabs into the thrust hub grooves.
10. Reinstall spark plug leads.

Page 1C-20 90-883064R02 JULY 2006

 General Information

Power Trim System

General Information
The power trim system is filled at the manufacturer and is ready for use.
Trim outboard through entire trim and tilt range several times to remove any air from the
system.
The trim system is pressurized and is not externally vented.
Power Trim Operation
With most boats, operating around the middle of the trim range will give satisfactory results.
However, to take full advantage of the trimming capability there may be times when you
choose to trim your outboard all the way in or out. Along with an improvement in some
performance aspects comes a greater responsibility for the operator, and this is being aware
of some potential control hazards.
The most significant control hazard is a pull or torque that can be felt on the steering wheel
or tiller handle. This steering torque results from the outboard being trimmed so that the
propeller shaft is not parallel to the water surface.

WARNING
Avoid possible serious injury or death. When the outboard is trimmed in or out
beyond a neutral steering condition, a pull on the steering wheel or tiller handle in
either direction may result. Failure to keep a continuous firm grip on the steering
wheel or tiller handle when this condition exists can result in loss of boat control
as the outboard can turn freely. The boat can now spin out or go into a very tight
maximum turn which, if unexpected, can result in occupants being thrown within
the boat or out of the boat.

Consider the following lists carefully.

1. Trimming In or Down Can:
• Lower the bow.
• Result in quicker planing off, especially with a heavy load or a stern heavy boat.
• Generally improve the ride in choppy water.
• Increase steering torque or pull.
• In excess, the bow of some boats will begin to plow with their bow in the water while
on plane. This can result in an unexpected turn in either direction (called bow steer-
ing or over-steering) if any turn is attempted or if a significant wave is encountered.

WARNING
Avoid possible serious injury or death. Adjust outboard to an intermediate trim
position as soon as boat is on plane to avoid possible ejection due to boat spin-out.
Do not attempt to turn boat when on plane if outboard is trimmed extremely in or
down and there is a pull on the steering wheel or tiller handle.

90-883064R02 JULY 2006 Page 1C-21

General Information

2. Trimming Out or Up Can:

• Lift the bow higher out of the water.
• Generally increase top speed.
• Increase clearance over submerged objects or a shallow bottom.
• Increase steering torque or pull at a normal installation height.
• In excess, can cause boat porpoising, bouncing or propeller ventilation.
• Cause engine overheating if any water intake holes are above the water line.

Trim In Angle Adjustment

Some outboard boats, particularly some bass boats, are built with a greater than normal
transom angle which will allow the outboard to be trimmed further in or under. This greater
trim under capability is desirable to improve acceleration, reduce the angle and time spent
in a bow high boat, and in some cases, may be necessary to plane off a boat with aft live
wells, given the variety of available propellers and height range of engine installations.
However, once on plane, the engine should be trimmed to a more intermediate position to
avoid a bow-down planing condition called plowing. Plowing can cause bow steering or
over-steering and inefficiently consumes horsepower. In this condition, if attempting a turn
or encountering a diagonal, moderate wake, a more abrupt turn than intended may result.
In rare circumstances, the owner may decide to limit the trim in. This can be accomplished
by repositioning the tilt stop pins into whatever adjustment holes in the transom brackets
is desired.

WARNING
Avoid possible serious injury or death. Adjust outboard to an intermediate trim
position as soon as boat is on plane to avoid possible ejection due to boat spin-out.
Do not attempt to turn boat when on plane if outboard is trimmed extremely in or
down and there is a pull on the steering wheel or tiller handle.

If an adjustment is required, a stainless steel tilt pin is available and should be inserted
through the desired pin hole. The non-stainless steel shipping bolt should not be used in this
application other than a temporary basis.

a - Optional tilt pin

Page 1C-22 90-883064R02 JULY 2006

 General Information

Trim Tab Adjustment

Propeller steering torque will cause the boat to pull in one direction. Steering torque is a
normal result from the outboard not being trimmed so the propeller shaft is parallel to the
water surface. The trim tab can help to compensate for this steering torque in many cases
and can be adjusted within limits to reduce any unequal steering effort.
NOTE: Trim tab adjustment will have little effect reducing steering torque if the outboard is
installed with the anti-ventilation plate approximately 50 mm (2 inches) or more above the
boat bottom.
Operate the boat at normal cruising speed trimmed to desired position. Turn the boat left
and right and note the direction the boat turns more easily.
If adjustment is necessary, loosen trim tab bolt and make small adjustments at a time. If the
boat turns more easily to the left, move the trailing edge of trim tab to the left. If the boat
turns more easily to the right move the trailing edge of trim tab to the right. Retighten bolt
and retest.

a - Trim tab

Compression Check
CAUTION
Compression/cylinder leakage tests must be performed with the ignition/injection
system disabled. To do this, the lanyard stop switch must be placed to the “OFF”
position.

Cylinder compression
Minimum 950 kPa, 9.5 kg/cm2 (135 psi)

IMPORTANT: Compression check should be done with throttle in WOT position.

1. Check valve clearance. Refer to Section 4A - Valve Clearance Adjustment. Adjust if
out of specification.
2. Warm up the engine. Remove all spark plugs.

90-883064R02 JULY 2006 Page 1C-23

General Information

3. Lubricate threads in cylinder head and on compression gauge. Install compression

gauge in spark plug hole.

110

a - Compression gauge
b - Adapter
Compression Gauge Snap-On EEPV303A
Adapter Snap-On MT26-18

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

4. Hold throttle plate at WOT and crank the engine over until the compression reading
peaks on the gauge. Record the reading.
5. Check and record compression of each cylinder. The highest and lowest reading
recorded should not differ by more than 15% (see example chart below). A reading
below 827 kPa (120 psi) might indicate a total engine wear problem.
Example of compression test differences:

Compression Test Difference

Condition Maximum Reading Minimum Reading
Good 1241 kPa (180 psi) 1117 kPa (162 psi)
Bad 1034 kPa (150 psi) 879 kPa (127.5 psi)

6. Remove compression gauge. Install spark plugs.

NOTE: Compression check is important because an engine with low or uneven compres-
sion cannot be tuned successfully to give peak performance. Therefore, it is essential that
improper compression be corrected before proceeding with an engine tuneup.

Page 1C-24 90-883064R02 JULY 2006

 General Information

Cylinder Leakage Testing

CAUTION
Compression/cylinder leakage tests must be performed with the ignition/injection
system disabled. To do this, the lanyard stop switch must be placed to the “OFF”
position.
NOTE: Cylinder leakage testing, along with compression testing, can help the mechanic
pinpoint the source of a mechanical failure by gauging the amount of leakage in an engine
cylinder. Refer to the manufacturer’s tester instructions for proper testing procedures.

a - Cylinder leakage tester (Snap-On EEPV309A)

NOTE: Spark plug hole is a 12 mm diameter. Use Snap-On MT26-18 adapter with valve
core removed.

Cylinder Leakage Tester Snap-On EEPV309A

Adapter Snap-On MT26-18

Analysis
Due to standard engine tolerances and engine wear, no cylinder will maintain a 0% of
leakage. It is important only that cylinders have somewhat consistent reading between
them. Differences of 15 to 30% indicate excessive leakage. Larger engines tend to have a
larger percentage of cylinder leakage than smaller engines.
If excessive leakage is present, first check that the piston is at top dead center of its
compression stroke. Leakage will naturally occur if the exhaust or intake valve is open.
To determine the cause of high percentage leaks, you must locate where the air is escaping
from. Listen for air escaping through the intake manifold, adjacent spark plug holes, exhaust
pipe, and crankcase fill plug. Use the following table to aid in locating the source of cylinder
leakage:

Air Escaping From: Indicates Possible Defective:

Intake manifold Intake valve
Exhaust system Exhaust valve
Crankcase fill plug Piston or rings
Cylinder Head gasket

90-883064R02 JULY 2006 Page 1C-25

General Information

Water Pressure Measurement

1. Warm up engine.
2. Remove plug.
3. Attach hose fitting and water pressure gauge to cylinder block.
NOTE: Water pressure measurements should be done on a warm engine with thermostat
operating 60° C (140° F).

Water Pump Pressure

24
c 22
20
b

Pump Pressure (psi)

18
16
14
12
10
8
6
4
2
a 0
0 1 2 3 4 5 6
RPM x 1000
a - Plug
b - Water pressure gauge
c - Fitting

Water Pressure Gauge 91-79250A2

Fitting 22-89772

Page 1C-26 90-883064R02 JULY 2006

 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 Light Gray Primer.
5. Allow a minimum of one hour dry time and no more than one week before applying the
finish coat.
6. Apply the finish coat using Mercury/Quicksilver EDP Propeller Black.

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.
1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine
growth, and rinse with water.
2. Wash gear housing with soap and water. Rinse with cold water.
3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint
blisters only. Feather edge all broken paint edges.
4. Clean gear housing thoroughly with DX-330 Wax and Grease Remover.
5. Spot repair surfaces where bare metal is exposed with DX-503 Alodine Treatment.
IMPORTANT: Do not use aerosol spray paints as the paint will not properly adhere
to the surface nor will the coating be sufficiently thick to resist future paint blistering.
6. Mix Epoxy Chromate Primer DP-90LF with equal part catalyst DP-402LF per the
manufacturer’s instructions. Allow proper induction period for permeation of the epoxy
primer and catalyst.
7. Allow a minimum of one hour drying time and no more than one week before the top coat
application.
8. Use Ditzler Urethane DU9300 for Mercury Black, DU34334 for Mariner Grey, DU35466
for Force Charcoal, DU33414M for Sea Ray White and DFHS 37372H for Verado Silver.
Catalyze all five colors with Ditzler DU5 catalyst mixed 1:1 ratio. Reduce with solvents
per Ditzler label.

90-883064R02 JULY 2006 Page 1C-27

General Information

CAUTION
Be sure to comply with instructions on the label for ventilation and respirators.
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.

Decal Removal/Application
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. Dishwashing liquid detergent without ammonia
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 sun-
light. Air and surface temperature should be between 15° C (60° F) and 38° C (100° F)
for best application.

SURFACE PREPARATION
IMPORTANT: Do not use a soap or any petroleum based solvents to clean application
surface.
Clean entire application surface with mild dishwashing liquid and water. Rinse surface
thoroughly with clean water.

Page 1C-28 90-883064R02 JULY 2006

 General Information

Decal Application
1. Mix 16 ml (1/2 oz.) of dishwashing liquid in 4 liter (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 its 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.

90-883064R02 JULY 2006 Page 1C-29

 Outboard Motor Installation

Important Information 1
Section 1D - Outboard Motor Installation D
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 1D-1 Single Outboard . . . . . . . . . . . . . . . . . . . . . 1D-9
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-2 Dual Outboards . . . . . . . . . . . . . . . . . . . . . 1D-10
Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . 1D-2 Shift and Throttle Cable Installation . . . . . . . 1D-10
Boat Horsepower Capacity . . . . . . . . . . . . . . 1D-2 Shift Cable Installation . . . . . . . . . . . . . . . 1D-10
Start in Gear Protection . . . . . . . . . . . . . . . . . 1D-3 Throttle Cable Installation . . . . . . . . . . . . . 1D-12
Selecting Accessories For The Outboard . . 1D-3 Trim-In Stop Adjustment - Power Trim
Installation Specifications . . . . . . . . . . . . . . . . 1D-3 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-14
Lifting Outboard . . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . 1D-15
Steering Cable . . . . . . . . . . . . . . . . . . . . . . . . . 1D-4 Wiring for SmartCraft Gauges - EFI Models 1D-16
Starboard Side Routed Cable . . . . . . . . . 1D-4 SmartCraft Wiring Harness Connection
Steering Cable Seal . . . . . . . . . . . . . . . . . . . . 1D-5 to the Engine 2005 and Prior . . . . . . . . . 1D-16
Steering Link Rod . . . . . . . . . . . . . . . . . . . . . . 1D-5 SmartCraft Wiring Harness Connection
Installing Outboard - Thumb Screw Models 1D-6 to the Engine 2006 and Newer . . . . . . . . 1D-17
Installing Outboard - Non-Thumb Screw Typical SmartCraft Installation
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-7 Configurations - EFI Models . . . . . . . . . . . . . 1D-17
2005 And Prior Wire Harness . . . . . . . . . . . . 1D-8 Single Engine Applications . . . . . . . . . . . . 1D-17
14 Pin Wire Harness . . . . . . . . . . . . . . . . . . . . 1D-9 Dual Engine Applications . . . . . . . . . . . . . 1D-18
Battery Cable Connections . . . . . . . . . . . . . . 1D-9

90-883064R02 JULY 2006 Page 1D-1

Outboard Motor Installation

Special Tools
Lifting Eye 91-90455 1
Outboard Mounting Kit 812432A4
Stainless Steel Tilt Pin 17-49930A 1

Electric Fuel Pump

If an electric fuel pump is used, the fuel pressure must not exceed 28 kPa (4 psi) at the engine.
If necessary, install a pressure regulator to regulate the pressure.

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 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.

Page 1D-2 90-883064R02 JULY 2006

 Outboard Motor Installation

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 Mercury Precision or Quicksilver Accessories have been specifically designed and
tested for this outboard.
Some accessories not manufactured or sold by Mercury Marine 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 b

Transom Opening “a” (Minimum)

Single engine (Remote) 48.3 cm (19 in.)
Single engine (Tiller) 76.2 cm (30 in.)
Dual engines 101.6 cm (40 in.)

Engine Center Line For Dual Engines “b”

Minimum 66 cm (26 in.)

90-883064R02 JULY 2006 Page 1D-3

Outboard Motor Installation

Lifting Outboard
Use lifting eye on engine.

Lifting Eye 91-90455 1

Steering Cable
Starboard Side Routed Cable
1. Lubricate the entire cable end with 2-4-C Marine Lubricant with Teflon.

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

2. Insert steering cable into tilt tube.

3. Torque nut to 47.5 Nm (35 lb. ft.).

Description Nm lb. in. lb. ft.

Nut 47.5 35

Page 1D-4 90-883064R02 JULY 2006

 Outboard Motor Installation

Steering Cable Seal

1. Mark tilt tube 6.4 mm (1/4 in.) from end. Install seal components.
2. Thread cap to the mark.

a b c d
a - 6.4 mm (1/4 in.) mark
b - Plastic spacer
c - O-ring seal
d - Cap

Steering Link Rod

1. Install steering link rod per illustration.

b
d
f
e

a
a - Special bolt (10-823919)
b - Nylon insert locknut (11-826709113)
c - Spacer (12-71970)
d - Flat washer (2)
e - Nylon insert locknut (11-826709113)
f - Use middle hole - steer outboard to the side to gain hole access
Description Nm lb. in. lb. ft.
Special bolt 27 20
Nylon insert locknut 27 20
Tighten until it seats,
Nylon insert locknut
then back 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 10-823919) and self-locking
nuts (“b” & “e” - Part Number 11-826709113). 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.

90-883064R02 JULY 2006 Page 1D-5

Outboard Motor Installation

Installing Outboard - Thumb Screw Models

WARNING
Outboard must be fastened to boat transom one of two ways: 1) permanently
fastened to transom with thumb screws, and mounting bolts (provided), or 2)
secured to the transom using the optional outboard mounting kit (shown below).
Should the outboard strike an underwater object or be steered into a sharp turn,
failure to fasten outboard correctly to the boat transom with mounting bolts or
optional mounting kit could result in outboard ejecting suddenly off boat transom
causing serious injury, death, boat damage, or loss of outboard.
IMPORTANT: Optional outboard mounting kits shown, must be used if outboard will
not be permanently fastened to the transom with mounting bolts.

a - Outboard mounting kit

Outboard Mounting Kit 812432A4

1. Center outboard on the transom. Install the outboard so that the anti-ventilation plate
is in line or within 25 mm (1 in.) below the bottom of the boat.

a - Anti-ventilation plate
b - 25 mm (1 in.) maximum

2. Fasten outboard with provided mounting hardware shown.

e
d
c

a
b
a - 1/2 in. diameter bolts (2) d - Marine Sealer (obtain locally)
b - Flat washers e - Thumb screws - tighten securely
c - Locknuts

Page 1D-6 90-883064R02 JULY 2006

 Outboard Motor Installation

Installing Outboard - Non-Thumb Screw Models

1. Attach engine mounting template to boat transom with tape.

2. Mark and drill four 13.5 mm (17/32 in.) mounting holes.

3. Install the outboard so that the anti-ventilation plate is in line or within 25 mm (1 in.) below
the bottom of the boat.

a - Anti-ventilation plate
b - 25 mm (1 in.) maximum

4. Fasten outboard with provided mounting hardware shown.

d
d
c c
b b a
a
a - 1/2 in. diameter bolts (2)
b - Flat washers
c - Locknuts
d - Marine Sealer (obtain locally)

90-883064R02 JULY 2006 Page 1D-7

Outboard Motor Installation

2005 And Prior Wire Harness

IMPORTANT: Warning Horn Requirement - The remote control or key switch
assembly must be wired with a warning horn. This warning horn is used with the
engine warning system.
1. Route the remote wire harness through the grommet into bottom cowl.
2. Connect the remote wire harness to the engine harness.
3. Push the wire harness connectors together. Push the retainer over the exposed ends
of the wire harness connectors and into the rubber retainer. Secure the rubber retainer
to the cylinder block

c b
BRN/WHT
GRN/WHT
BLU/WHT

TAN
GRN/WHT
BLU/WHT

a - Power trim connections

b - Rubber sleeve - place harness connectors inside
c - Retainer - push over connector ends

Page 1D-8 90-883064R02 JULY 2006

 Outboard Motor Installation

14 Pin Wire Harness

IMPORTANT: Warning Horn Requirement - The remote control or key switch
assembly must be wired with a warning horn. This warning horn is used with the
engine warning system.
1. Route the remote wire harness through the grommet into bottom cowl.
2. Connect the remote wire harness connector to the 14 pin engine harness connector.
Ensure the connector is locked into 14 pin engine harness connector.
3. Secure the remote wire harness with the retainer.

b c

12217

a - Remote wiring harness

b - Retainer
c - 14 Pin connector
Battery Cable Connections
Single Outboard
a

(+)

(--) c

a - Red sleeve (positive)

b - Black sleeve (negative)
c - Starting battery

90-883064R02 JULY 2006 Page 1D-9

Outboard Motor Installation

Dual Outboards
Connect a common ground cable between negative (--) terminals on starting batteries. The
wire size must be the same as engine battery cables.

(--)

(--)

a - Ground cable - connect between negative (--) terminals

Shift and Throttle Cable Installation

Install cables into the remote control following the instructions provided with the remote
control.
NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when
the remote control handle is moved out of neutral.
Shift Cable Installation
1. Position remote control into neutral.
2. Remove access cover from side of bottom cowl.

a
a - Access cover

Page 1D-10 90-883064R02 JULY 2006

 Outboard Motor Installation

3. Shift outboard into neutral.

4. Measure the distance between pin and center of lower hole.

b c
a - Distance between pin and center of lower hole
b - Pin
c - Lower hole

5. Fit shift cable through rubber grommet.

6. Push in on the cable end until resistance is felt.

7. While pushing in on the cable end, adjust the cable barrel to attain the measured
distance taken in Step 4.

b
a - Adjust cable barrel to attain the measured distance taken in Step 4
b - Cable barrel

90-883064R02 JULY 2006 Page 1D-11

Outboard Motor Installation

8. Place cable barrel into the barrel holder. Fasten cable with retainer.

b a

a - Place barrel into barrel holder

b - Retainer

9. Check shift cable adjustments as follows:

a. Shift remote control into forward. The propeller shaft should be locked in gear. If not,
adjust the barrel closer to the cable end.
b. Shift remote control into neutral. The propeller shaft should turn freely without drag.
If not, adjust the barrel away from the cable end. Repeat steps a and b.
c. Shift remote control into reverse while turning propeller. The propeller shaft should
be locked in gear. If not, adjust the barrel away from the cable end. Repeat steps a
through c.
d. Shift remote control back to neutral. The propeller shaft should turn freely without
drag. If not, adjust the barrel closer to the cable end. Repeat steps a through d.
Throttle Cable Installation
1. Position remote control into neutral.
N

2. Fit throttle cable through rubber grommet.

Page 1D-12 90-883064R02 JULY 2006

 Outboard Motor Installation

3. Install throttle cable with retainer pin. Lock retainer pin in place.
4. Place throttle cable onto the throttle lever pin. Lock in place with retainer.

b
a - Throttle cable
b - Retainer
5. Adjust cable barrel until the center of the roller lines up with the alignment mark on
the cam.

a - Cable barrel
b - Alignment mark
c - Roller

90-883064R02 JULY 2006 Page 1D-13

Outboard Motor Installation

6. Fasten control cables with the cable latch.

7. Install the access cover.

Trim-In Stop Adjustment - Power Trim Models

If an adjustment is required, a stainless steel tilt pin is available and should be inserted
through the desired pin hole. The non-stainless steel shipping bolt should not be used in this
application other than a temporary basis.

a - Tilt pin
Stainless Steel Tilt Pin 17-49930A 1

Page 1D-14 90-883064R02 JULY 2006

 Outboard Motor Installation

Trim Tab Adjustment

The trim tab can be adjusted within limits to help compensate for steering torque.
Adjust trim tab as follows:
1. If boat tends to pull to the right, move the rear edge of the trim tab to the right.
2. If boat tends to pull to the left, move the rear edge of the trim tab to the left.

NOTE: Trim tab adjustment will have little effect reducing steering torque if the
anti-ventilation plate is raised 50 mm (2 in.) or more above the boat bottom.

90-883064R02 JULY 2006 Page 1D-15

Outboard Motor Installation

Wiring for SmartCraft Gauges - EFI Models

SmartCraft Wiring Harness Connection to the Engine 2005 and Prior
1. Cut out the harness opening in the front rubber grommet.
2. Route the SmartCraft wiring harness into the bottom cowl and connect as shown.
c

a - Front rubber grommet - cut out harness opening

b - SmartCraft harness
c - Connection for SmartCraft harness

Page 1D-16 90-883064R02 JULY 2006

 Outboard Motor Installation

SmartCraft Wiring Harness Connection to the Engine 2006 and Newer

1. Cut out the harness opening in the front rubber grommet.
2. Route the SmartCraft wiring harness into the bottom cowl.
3. Connect the SmartCraft wiring harness to the engine harness connector on the front of
the engine.

b c

d
e

23886

a - Remote wiring harness

b - Retainer
c - 14 Pin connector
d - Connection for SmartCraft harness
Typical SmartCraft Installation Configurations - EFI Models
Single Engine Applications

c d

a b

a - Engine
b - Wiring harness SC1000 2RSL
c - System monitor
d - System tachometer
e - System Link gauge connection

90-883064R02 JULY 2006 Page 1D-17

Outboard Motor Installation

Dual Engine Applications

a c d e f
b

a - Port engine
b - Starboard engine
c - Wiring harness SC1000 2RSL
d - System Link gauge connection
e - System tachometer
f - System monitor

Page 1D-18 90-883064R02 JULY 2006

 Ignition

Electrical
Section 2A - Ignition
Table of Contents
2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Ignition Test Procedures . . . . . . . . . . . . . . . . . . 2A-9
A
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-3 Ignition Troubleshooting . . . . . . . . . . . . . . . . . . 2A-10
Ignition Coil Mounting . . . . . . . . . . . . . . . . . . . . 2A-4 Ignition Diagnostic Procedures . . . . . . . . . . . . 2A-10
Serial Number 0T979999 And Below . . . . 2A-4 Testing Ignition Coil . . . . . . . . . . . . . . . . . . . . . . 2A-10
Serial Number 0T980000 And Up . . . . . . 2A-6 0T979999 And Below . . . . . . . . . . . . . . . . . 2A-10
Ignition Description . . . . . . . . . . . . . . . . . . . . . . 2A-8 0T980000 And Up . . . . . . . . . . . . . . . . . . . . 2A-12
Electronic Spark Trigger (EST) Description . 2A-8 Ignition Coil Removal And Installation . . . . . . 2A-14
Electronic Spark Trigger (EST) Ignition
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-9

90-883064R02 JULY 2006 Page 2A-1

Ignition

Special Tools
1. DMT 2000 Digital Multimeter Tachometer P/N 91-892647A01

Page 2A-2 90-883064R02 JULY 2006

 Ignition

Specifications
Type Capacitor Discharge Ignition
Spark Plug:
Type Champion RA8HC
Gap 1.0 mm (0.040 in.)
Hex Size 16 mm (5/8 in.)
Torque 17 Nm (150 lb. in.)
Hole Size 12 mm
Firing Order 1-2-3
Ignition Timing:
@ Idle Controlled by ECM
@ 1800 - 2000 17° B.T.D.C.
@ WOT (6000 RPM) 28° B.T.D.C.
Stator Resistance 0.20 - 0.30 Ω (yellow - yellow)
Crank Position Sensor (CPS)
Resistance 300 - 350 Ω (red - white)
Ignition Coil Resistance:
0T979999 And Below
Internal Shielding 0 - 10.0 kΩ (Pin A - mounting bracket)
Electronic Spark Trigger (EST) 8.5 - 12 kΩ (Pin B - Pin C)
Secondary 3.0 - 7.0 kΩ (Pin A - coil tower)
Ignition High Tension Lead/Boot
System Resistance 0.600 - 1.100 kΩ
Readings taken @ 0T980000 And Up
20° C (68° F) Primary 0.25 Ω ± 10% (Pin D - Pin E)
Secondary 1.0 kΩ ± 20% (Pin C and coil tower)
Electronic Spark Trigger (EST) 8.5 - 12 kΩ (Pin A - Pin B)
ECM Engine RPM Limiter
Fuel/Spark Cutout On Cylinder #2 6225 RPM
Fuel/Spark Cutout On All Cylinders 6350 RPM
ECM Overheat RPM Control Guardian is active. Power limit will vary with level
of overheat.
ECM Low Oil Pressure RPM Contol Guardian is active. Engine power is limited to 10%
of maximum (approximately 2000 RPM).
See Graph in Section 3B - EFI
MAT/ECT Temperature Sensor See Table in Section 3B - EFI
Manifold Absolute Pressure (MAP)
Sensor Resistance 10.0 - 13.5 Ω
Fuel Injector Resistance 81 - 99 Ω (Pin 85 - Pin 86)
Main Power Relay 24 - 30 Ω between pins
Idle Air Control (IAC)
Throttle Position Sensor Range 0.39 - 1.00 volts
Output Voltage @ Idle 3.66 - 4.80 volts
Output Voltage @ WOT

90-883064R02 JULY 2006 Page 2A-3

Ignition

Ignition Coil Mounting

Serial Number 0T979999 And Below

1
13

11 16 15
25
17

66
9
3 18 14 8
10

19
4
11 7
6
5

2 6 10

12

Page 2A-4 90-883064R02 JULY 2006

 Ignition

Ignition Coil Mounting

Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
1 1 Coil plate
2 3 Ignition coil
3 3 High tension cable
4 6 Spacer
5 6 Nut 3.4 30
6 3 Trim relay
7 3 Bracket
8 3 Grommet
9 3 Bushing
10 3 Screw 6.8 60
11 2 J clip
12 1 Trim harness
13 3 Bushing
14 3 Grommet
15 1 Cable
16 1 Washer
17 1 Screw 5.1 45
18 3 Screw 8.5 75
19 3 Washer

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

25 Liquid Neoprene N/A 92-25711--3

66 Loctite 242 92-809821 92-809821

90-883064R02 JULY 2006 Page 2A-5

Ignition

Ignition Coil Mounting

Serial Number 0T980000 And Up

18
17
15

4
2 1
11
5
12

4
2
13
14

2
9
5
16

8 10
16
7
3 19
6
2640

Page 2A-6 90-883064R02 JULY 2006

 Ignition

Ignition Coil Mounting

Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
1 1 Coil plate
2 3 Ignition coil
3 3 High tension cable
4 4 Spacer
5 4 Screw 6.8 60
6 1 Relay
7 1 Bracket
8 1 Grommet
9 1 Bushing
10 1 Screw 6.8 60
11 2 Bushing
12 2 Grommet
13 3 Washer
14 3 Screw 8.5 75
15 1 Screw 5.1 45
16 3 Spacer
17 1 Washer
18 1 Cable
19 1 Screw 6.8 60

90-883064R02 JULY 2006 Page 2A-7

Ignition

Ignition Description
When the ignition key switch is turned to the RUN position, battery voltage is applied to both
the Electronic Control Module (ECM) through the purple wire and the main power relay
through the red/purple wire. As the ECM receives the RUN signal it internally completes the
ground circuit of the main relay for a period of two seconds, energizing the ignition/injection
systems for start-up. As the engine is cranked with the starter motor, the ECM receives the
RUN signal from the Crank Position Sensor (CPS) and completes the ground circuit to the
main relay for engine operation.
With the main relay closed, 12 volts is transferred through the 20 ampere main relay fuse
to the positive terminal of all ignition coil primary windings. The negative terminals of the
ignition coil primaries are connected to the engine ground through the coils internal driver,
which is triggered by the ECM. With the coil drivers closed, an electric magnetic field is
allowed to build up within the ignition coil.
As the flywheel rotates, the CPS senses the location of the 54 teeth on the flywheel and
supplies the trigger signal information to the ECM. The ECM utilizes the CPS information
and determines when to remove the trigger signal from the coil driver of each ignition coil.
The coil driver then opens the coil primary ground circuit which allows its magnetic field to
rapidly collapse across the coil secondary winding which induces a high voltage charge of
approximately 50,000 volts, that fires the spark plug.

Electronic Spark Trigger (EST) Description

The negative terminals of the ignition coil primaries are connected to the engine ground
through the coil’s internal driver, which is triggered by the ECM. With the coil drivers closed,
an electric magnetic field is allowed to build up within the ignition coil.
As the flywheel rotates, the CPS senses the location of the 54 teeth on the flywheel and
supplies the trigger signal information to the ECM. The ECM utilizes the CPS information
and determines when to remove the trigger signal from the coil driver of each ignition coil.
The coil driver then opens the coil primary ground circuit which allows its magnetic field to
rapidly collapse across the coil secondary winding which induces a high voltage charge of
approximately 50,000 volts that fires the spark plug.

Page 2A-8 90-883064R02 JULY 2006

 Ignition

Electronic Spark Trigger (EST) Ignition Coils

7341

0T979999 and below 0T980000 and up

Ignition Test Procedures

WARNING
DANGER – High voltage/shock hazard! Do not touch ignition components and/or
metal test probes while the engine is running and/or being cranked. Stay clear of
the spark plug leads. To assure personal safety, each individual spark plug lead
should be grounded to the engine.

WARNING
When testing or servicing the ignition system, high voltage is present. Do not touch
or disconnect any ignition parts while the engine is running, while the key switch
is on or while the battery cables are connected.

CAUTION
Failure to comply with the following items may result in damage to the ignition system.

1. Do not reverse the battery cable connections. The battery negative (–) cable is ground.
2. Do not spark the battery terminals with the battery cable connections to check polarity.
3. Do not disconnect the battery cables while the engine is running.
4. Do not crank the engine with ignition coils/coil mounting plate not grounded.

CAUTION
To protect against meter and/or component damage, observe the following
precautions:
w All components must be grounded during tests. Running or cranking engine
with ignition coils/coil mounting plate ungrounded may damage components.

IMPORTANT: The metal housing of the ECM is isolation mounted and must not be
externally grounded. Should the housing become externally grounded, the engine
will not run until the ground is removed and battery cables are momentarily disconnected
from the battery to reset the ECM.

90-883064R02 JULY 2006 Page 2A-9

Ignition

Ignition Troubleshooting
Refer to Section 3B - Troubleshooting and Diagnostics for complete system
troubleshooting/diagnostics procedures.

Ignition Diagnostic Procedures

NOTE: With the engine running, use an inductive timing light to check the spark advance
of each cylinder as the throttle is opened and closed. If the timing advances and retards on
each cylinder, the ignition system is most likely functioning properly.
IMPORTANT: If the outboard appears to have an ignition system failure, it is
recommended that before beginning in-depth troubleshooting:
a. Ensure that the engine is in a mechanically sound condition. Fuel system,
cylinder compression, etc.
b. Check all the engine ground leads for loose or corroded connections.
c. Disconnect and reconnect the ignition harness connectors to verify proper
continuity.

Testing Ignition Coil

0T979999 And Below
RESISTANCE TESTS
Readings may vary slightly due to temperature changes. Readings listed taken at 20° C (68° F).
NOTE: If using a digital multimeter, turn the selector switch to W. Allow the meter to
auto-range.
DMT 2000 Digital Multimeter Tachometer 91-892647A01

ELECTRONIC SPARK TRIGGER (EST) TO EST GROUND

DC BA

b a

a - Red meter test lead

b - Black meter test lead
Meter Scale Reading
Meter Test Leads
(Analog) (W)
Red Black
R x 1k 8 5 - 12
8.5 12.0k
0k
Pin B Pin C

NOTE: Ohm readings may not be in the range specified because of sensitivity of your
multimeter. Meter should show almost full continuity or near zero resistance condition.

Page 2A-10 90-883064R02 JULY 2006

 Ignition

HIGH TENSION LEAD REMOVAL/INSTALLATION

Removal
1. Slightly twist the high tension lead while removing.
Installation
1. Push the high tension lead on until it snaps in place.
NOTE: High tension leads must be removed before testing. Leads contain 5k ohm resistor.

a - High tension lead

HIGH TENSION LEAD RESISTANCE

a - Coil end
b - Spark plug end

Meter Scale Reading

Meter Test Leads
(Analog) (W)
Red Black
R x 100 0 600 - 1.100k
0.600 1 100k
Coil end Plug end

90-883064R02 JULY 2006 Page 2A-11

Ignition

IGNITION COIL (SECONDARY)

DC BA

b
a

a - Pin A
b - Coil tower
Meter Scale Reading
Meter Test Leads
(Analog) (W)
Red Black
R x 1k 30-7
3.0 7.0
0
Coil tower Pin A

0T980000 And Up
RESISTANCE TESTS
Readings may vary slightly due to temperature changes. Readings listed taken at 20° C (68° F).
NOTE: If using a digital multimeter, turn the selector switch to W. Allow the meter to
auto-range.
DMT 2000 Digital Multimeter Tachometer 91-892647A01

COIL PRIMARY
1. Connect the black meter lead to the coil battery ground terminal.
2. Connect the red meter lead to the coil battery positive terminal.

a
b

7365

a - Coil battery ground terminal

b - Coil battery positive terminal

Meter Scale Reading

Meter Test Leads
(Analog) (W)
Red Black
Coil battery positive Coil battery negative R x 1k 0.25 ± 10%
terminal terminal

Page 2A-12 90-883064R02 JULY 2006

 Ignition

COIL SECONDARY
1. Connect the red meter lead to the coil tower.
2. Connect the black meter lead to the secondary ground terminal.

7369

a - Coil tower
b - Secondary ground terminal
Meter Scale Reading
Meter Test Leads
(Analog) (W)
Red Black
Secondary ground R x 1k 1.0 ± 20%
Coil tower
terminal

ELECTRONIC SPARK TRIGGER (EST)

1. Connect the red meter lead to the EST high terminal.
2. Connect the black meter lead to the EST low terminal.

a
b

7763

a - EST high terminal

b - EST low terminal

Meter Scale Reading

Meter Test Leads
(Analog) (W)
Red Black
R x 1k 8 5 - 12
8.5 12.0k
0k
EST high terminal EST low terminal

90-883064R02 JULY 2006 Page 2A-13

Ignition

Ignition Coil Removal And Installation

WARNING
Avoid serious injury or death from fire or explosion caused by damaged spark plug
boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel vapors
under the engine cowl. To avoid damaging spark plug boots, do not use any sharp
object or metal tool such as pliers, screwdriver, etc. to remove spark plug boots.

1. Disconnect the spark plug leads from the spark plugs.

2. Disconnect the ignition coil harness connectors.
3. Remove the ignition coil mounting screws.
4. Reverse the steps for installation.
c
d

b
a

58980

a - Spark plug lead (3)

b - Ignition coil harness connector (3)
c - Ignition coil mounting nut (6)
d - Ignition coil (3)

Description Nm lb. in. lb. ft.

Ignition Coil Mounting Nut 3.4 30

Page 2A-14 90-883064R02 JULY 2006

 Charging and Starting System

Electrical
Section 2B - Charging and Starting System
Table of Contents
2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-2 Flywheel Removal/Installation . . . . . . . . . . . . . 2B-18
B
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-18
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-4 Flywheel Installation . . . . . . . . . . . . . . . . . . 2B-20
Electrical Components . . . . . . . . . . . . . . . . . . . 2B-6 Stator Removal/Installation . . . . . . . . . . . . . . . 2B-21
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10 Voltage Regulator/Rectifier Removal/
Battery Charging System . . . . . . . . . . . . . . . . . 2B-11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-22
Description (20 Ampere) . . . . . . . . . . . . . . 2B-11 Starting System Components . . . . . . . . . . . . . 2B-23
Wiring Diagram (20 Ampere) . . . . . . . . . . . 2B-11 Description . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-23
Charging System Description . . . . . . . . . . . . . 2B-12 Troubleshooting the Starting Circuit . . . . . . . . 2B-23
Flywheel Assembly . . . . . . . . . . . . . . . . . . . 2B-12 Starter Solenoid Test . . . . . . . . . . . . . . . . . . 2B-24
Stator Assembly . . . . . . . . . . . . . . . . . . . . . . 2B-12 Starter Motor Servicing . . . . . . . . . . . . . . . . . . . 2B-27
Voltage Regulator/Rectifier Assembly . . . 2B-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-27
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-27
Battery Charging System Troubleshooting . . 2B-13 Cleaning and Inspection . . . . . . . . . . . . . . . 2B-29
Alternator System Test . . . . . . . . . . . . . . . . 2B-14 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-30
Stator Resistance Test - 20 Ampere Stator . 2B-15 Brush Replacement . . . . . . . . . . . . . . . . . . . 2B-32
Suppression Diode Tests . . . . . . . . . . . . . . 2B-15 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-33
Regulator/Rectifier Diode Test . . . . . . . . . . 2B-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-36

90-883064R02 JULY 2006 Page 2B-1

Charging and Starting System

Special Tools
1. Flywheel Holder P/N 91-83163M

2. Flywheel Puller P/N 91-83164M

3. DMT Digital Multimeter Tachometer P/N 91-892647A01

Page 2B-2 90-883064R02 JULY 2006

 Charging and Starting System

Specifications
Alternator Type: Single phase (12 pole)
Charging
20 Ampere Electric Alternator Output 12.6 v - 20 amperes (252 watts)
System
(rectified/regulated)
Readings taken @
Stator Resistance 0.20 - 0.30 ohms (yellow - yellow)
20° C (68° F)
Quicksilver Tachometer Setting “6P” or “4”
Electric Start:
Starter Type Bendix
Starting Output 1.1 kW
System Ampere Draw Under:
(Load) 174.0 amperes
(No Load) 23.7 amperes
Battery Rating
Minimum Requirement 465 Marine Cranking Amperes (MCA)
or 350 Cold Cranking Amperes (CCA)
For operation below 0° C (32° F) 1000 Marine Cranking Amperes (MCA) or 775
Battery Cold Cranking Amperes (CCA)
Ampere-Hours (Ah) Minimum
For operation above 0° C (32° F) 70
For operation below 0° C (32° F) 105

90-883064R02 JULY 2006 Page 2B-3

Charging and Starting System

Flywheel
2 3

6
110

7 9 8
10

15
4
16

19

11

13
5
14

12

17
18

20

Page 2B-4 90-883064R02 JULY 2006

 Charging and Starting System

Flywheel
Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
1 1 Flywheel cover
2 4 Screw (M6 x 25) 8.5 75
3 1 Decal - EPA information (See note)
4 1 Flywheel
5 1 Driven gear
6 1 Decal - Warning spinning flywheel
7 1 Decal - Timing marks
8 1 Decal - Warning - neutral
9 1 Nut 155.9 115
10 1 Washer
11 3 Screw (M5 x 30) 9.6 85
12 1 Stator
13 1 Load ring
14 1 Drive gear
15 1 Screw (M10 x 40) 38 28
16 1 Washer
17 1 Key
18 1 Key
19 1 Timing belt
20 1 Cable tie
NOTE: The EPA label has important information regarding EPA emission regulations.
Replace any missing or unreadable EPA label.

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

90-883064R02 JULY 2006 Page 2B-5

Charging and Starting System

Electrical Components

66

66

25

25

Page 2B-6 90-883064R02 JULY 2006

 Charging and Starting System

Electrical Components
Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
1 3 Screw (M6 x 25) 5.1 45
2 1 Plate
3 3 Washer
4 3 Grommet
1 ECM (30)
5 1 ECM (40)
1 ECM (40 Bodensee)
6 3 Bushing
7 2 Screw (M6 x 14) 5.1 45
8 1 Bracket
9 1 Retainer
10 1 Retainer
11 1 Plate
12 3 Screw (M6 x 16) 8.5 75
13 1 Diode adapter cable
14 1 Brace
15 2 Screw (M6 x 14) 5.1 45
16 1 Solenoid plate
17 1 Screw (M6 x 14) 5.1 45
18 1 Bracket
19 1 Solenoid
20 1 Cable (21.6 cm [8-1/2 in.])
21 2 Nut 6.8 60
22 1 Battery cable (Positive)
23 1 Boot (Red)
24 1 Engine wiring harness
4 Fuse (20 ampere)
25
1 Fuse (15 ampere)
26 1 Cover
27 AR Cable tie
28 1 Plug (Male)
29 1 Crank position sensor
30 2 Screw (M5 x 16) 5.1 45
34 1 Voltage regulator
35 1 Bracket
36 1 Foam pad
37 2 Screw (M6 x 40) 8.5 75
38 1 Pressure switch 8.5 75
39 1 Starter motor (See breakdown on starter motor)
310 1 Nut (1/4-20) 6.8 60
311 1 Battery cable (Negative)
312 1 J clip

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Charging and Starting System

Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
40 3 Screw (M8 x 45) 29.4 21.7
41 4 Spark plug (RA8HC) 21.1 20
42 1 Extension harness (Handle)
43 1 J clamp
44 1 Screw (M5 x 12) 5.1 45
45 1 Cable

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

6 Dielectric Grease N/A 92-823506-1

25 Liquid Neoprene N/A 92-25711-3

Loctite 567 PST Pipe

9 92-809822 92-809822
Sealant

66 Loctite 242 92-809821 92-809821

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 Charging and Starting System

Electrical Components

66

66

25

25

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Charging and Starting System

Starter Motor

2
3

1 6

11
10

9
4 7

Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
1 1 Starter motor
2 2 Thru-bolt 8.0 70
3 1 Drive kit
4 1 Armature
5 1 Pinion
6 1 Drive cap
7 1 Commutator cap
8 1 Brush & spring kit
9 1 Brush holder
10 2 Screw
11 1 Decal - Warning - High voltage

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 Charging and Starting System

Battery Charging System

Description (20 Ampere)
The battery charging system components are the flywheel, stator, regulator/rectifier, and
battery. Alternating current generated in stator charge coils, flows to the regulator/rectifier,
which changes the alternating current to a regulated direct current for charging the battery.

Wiring Diagram (20 Ampere)

YEL YEL b
e

RED

GRY RED
d
YEL BLK
RED

YEL
BLK
RED
f
c
a - Stator
b - Voltage regulator/rectifier
c - Connector
d - To engine ground
e - To battery positive terminal (Red)
f - To battery negative terminal (Black)

Wire Color Abbreviations

BLK Black GRY Grey
RED Red YEL Yellow

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Charging and Starting System

Charging System Description

Flywheel Assembly

The flywheel assembly contains six permanently charged magnet segments which are
bonded and retained to the inner wall of the flywheel. Each magnet contains a north and a
south pole providing a 12 pole system.

Stator Assembly

58489

The stator assembly located under the flywheel contains the battery charge coils. As the
flywheel permanent magnets pass the stator coil windings, alternating current (AC) is
produced at each coil winding when magnet polarity changes. South to north, north to
south, etc.

Voltage Regulator/Rectifier Assembly

The voltage regulator converts the alternating current from the stator to direct current (DC)
that can be stored in the battery.

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 Charging and Starting System

Battery

A 12 volt battery with a minimum rating of 465 Marine Cranking Amperes (MCA) or 350 Cold
Cranking Amperes (CCA) is used for storing DC voltage. For operation below 0° C (32° F)
a rating of 1000 Marine Cranking Amperes (MCA) or 775 Cold Cranking Amperes (CCA)
is recommended.

Battery Charging System Troubleshooting

CAUTION
The charging system may be damaged by: 1) reversed battery cables, 2) an open
circuit, such as a broken wire or loose connection.
A fault in the battery charging system usually will cause the battery to become
undercharged. Check the battery electrolyte level, and charge the battery.
If the battery will not accept a satisfactory charge, replace the battery.
If the battery accepts a satisfactory charge, determine the cause of the charging system
problem as follows.
1. Check for correct battery polarity (red cable to battery positive [+] terminal). If polarity
was incorrect, check for damaged regulator/rectifier. Refer to Regulator/Rectifier
Diode Test.
2. Check for loose or corroded battery connections.
3. Visually inspect the wiring between the stator and the battery for cuts, chafing, and a
disconnected, loose or corroded connection.
4. Excessive electrical load from too many accessories will cause the battery to run down.
If visual inspection determines that the battery connections and wiring are OK, perform the
following stator and regulator/rectifier tests.

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Charging and Starting System

Alternator System Test

20 AMPERE STATOR
1. Check the battery voltage at the battery with the engine running.
2. If the battery voltage is above 15.0 volts, replace the voltage regulator/rectifier. Check
the condition of the battery as overcharging may have damaged the battery.
3. If the battery voltage is below 12.5 volts, charge the battery. If the battery cannot be
satisfactorily charged, replace the battery.
4. If the battery accepts a satisfactory charge, check the battery voltage while cranking the
engine. If the cranking voltage is not acceptable, replace the battery.
5. If the cranking voltage is acceptable, disconnect the red voltage regulator connector.
6. Connect the red (+) ammeter lead to the red voltage regulator wire, and the black (–)
ammeter lead to the red wiring harness wire.
7. Secure the stator wires away from the flywheel.
8. With the engine running at the indicated RPM’s, the ammeter should indicate the
following appropriate amperes:
20

18
Alternator current (Amperes)

16

14

12

10

0
0 1 2 3 4 5 6
RPM x 1000

9. A reading of 19.5 amperes at 5000 RPM indicates the charging system is functioning
properly.
10. If the ammeter reads less than required amperes @ 5000 RPM, test the stator. Refer
to Stator Resistance Test. If the stator tests OK, replace the rectifier/regulator.

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 Charging and Starting System

Stator Resistance Test - 20 Ampere Stator

Meter Scale Reading

Meter Test Leads
(Analog) (W)
Red Black
Rx1 0 20 - 0
0.20 0.30
30
Yelllow Yellow

NOTE: If using a digital multimeter, turn the selector switch to W. Allow the meter to
auto-range.
DMT Digital Multimeter Tachometer 91-892647A01

Suppression Diode Tests

The suppression diode is located between the brown start solenoid lead, the yellow/red key
switch lead within the engine harness, and connects to engine ground. The purpose of the
suppression diode is to eliminate the inductive spike created as the start solenoid is
de-energized when the key switch is turned from “START” to “RUN”.
Symptoms of a failed suppression diode:
1. Open circuit - Longer crank times during engine start-up (3 seconds warm engine).
2. Short circuit - Blown fuse #3 (Main Power Relay/Accessory).

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Charging and Starting System

NOTE: If battery leads are connected in reverse polarity, the diode will short out and fail.

BLK

BRN YEL/RED

DIODE TEST
BLK RED YEL/RED BRN BLK
YEL/RED X 0 v OR SHORT 0.4 - 0.8 v
BRN 0 v or SHORT X 0.4 - 0.8 v
BLK OUCH, OL, ∞ OUCH, OL, ∞ X

RESISTANCE TEST
BLK RED YEL/RED BRN BLK
YEL/RED X < 0.5 W 1 - 3MW
BRN < 0.5 W X 1 - 3MW
BLK OUCH, OL, ∞ OUCH, OL, ∞ X

Regulator/Rectifier Diode Test

ANALOG METER
NOTE: Voltage regulator/rectifier specifications are given for informational purposes only.
Use the appropriate troubleshooting techniques previously mentioned to find the faulty
component in the charging system.
BLK

GRY
YEL

YEL

RED

Wire Color Abbreviations

BLK Black GRY Grey
RED Red YEL Yellow
Diode Test:
1. Set the ohmmeter to R x 10 scale.
2. Connect the red (+) meter lead to the red regulator lead.
3. Connect the black (–) meter lead to either yellow regulator lead.
Test Results:
100 - 400 OHMS

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 Charging and Starting System

Diode Test:
1. Set the ohmmeter to R x 1k scale.
2. Connect the black (–) meter lead to the red regulator lead.
3. Connect the red (+) meter lead to the yellow regulator lead. Test. Then change the red
(+) meter lead to the other yellow regulator lead for the 2nd test reading.
Test Results (1st reading):
20,000 to ∞ OHMS
Test Results (2nd reading):
∞ OHMS (No needle movement)
SCR Test:
1. Set the ohmmeter to R x 1k scale.
2. Connect the red (+) meter lead to the regulator case.
3. Connect the black (–) meter lead to one yellow regulator lead. Test. Connect the black
(–) meter lead to the other yellow regulator lead.
Test Results (Both tests):
8,000 - 15,000 OHMS (8k - 15k)
Tachometer Circuit Test:
1. Set the ohmmeter to R x 1k scale.
2. Connect the red (+) meter lead to the grey regulator lead.
3. Connect the black (–) meter lead to the regulator case.
Test Results:
10,000 - 50,000 OHMS (10k - 50k)

DIGITAL METER
NOTE: Voltage regulator/rectifier specifications are given for informational purposes only.
Use the appropriate troubleshooting techniques previously mentioned to find the faulty
component in the charging system.
BLK

GRY
YEL

YEL

RED

Wire Color Abbreviations

BLK Black GRY Grey
RED Red YEL Yellow

Diode Test:
1. Set the meter to .
2. Connect the black (–) meter lead to the red regulator lead.
3. Connect the red (+) meter lead to either yellow regulator lead.
Test Results:
0.4 - 0.8 v

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Charging and Starting System

Diode test:
1. Set the meter to .
2. Connect the red (+) meter lead to the red regulator lead.
3. Connect the black (–) meter lead to either yellow regulator lead.
Test Results (1st reading):
∞ or OUCH or OL
SCR Test:
1. Set the meter to .
2. Connect the black (–) meter lead to the regulator case.
3. Connect the red (+) meter lead to either yellow regulator lead.
Test Results (Both tests):
1.5 v - ∞ or OUCH or OL

Flywheel Removal/Installation
WARNING
The engine could possibly start when turning the flywheel during removal and
installation. To prevent this type of accidental engine starting and possible serious
injury, always remove the spark plug leads from the spark plugs.
Removal
1. Remove the flywheel cover.

a - Flywheel cover
b - Screw (M6 x 25) (4)

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 Charging and Starting System

2. Loosen the flywheel nut. Hold the flywheel using the flywheel holder.
3. Remove the nut and washer.
NOTE: Removal of the nut may require the use of an impact tool.

c
d

a - Flywheel holder
b - Breaker bar with 30 mm socket
c - Nut
d - Washer
Flywheel Holder 91-83163M

4. Loosen the flywheel using a puller. Remove the flywheel and key.
NOTE: Apply a small amount of grease to the end of the crankshaft before installing the puller.

c
b

58815

58227
a - Flywheel puller
b - Flywheel
c - Key
Flywheel Puller 91-83164M

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Charging and Starting System

Flywheel Installation
1. Place the flywheel key into the slot.
2. Install the flywheel. Apply oil to the threads on the flywheel nut.
3. Install the washer and nut.
4. Hold the flywheel using the flywheel holder and tighten the nut to the specified torque.
d
110
c

a
b

58227

a - Key
b - Flywheel
c - Washer
d - Nut
e - Torque wrench with 30mm socket
f - Flywheel holder
Flywheel Holder 91-83163M

Description Nm lb. in. lb. ft.

Flywheel nut 155.9 115

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

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 Charging and Starting System

Stator Removal/Installation
1. Remove the flywheel. Refer to Flywheel Removal.
2. Disconnect the stator wires. The 2 pin connector disconnects from the voltage regulator.
3. Remove the stator mounting screws.
4. Reverse the steps for installation. Refer to the wiring diagram in Section 8 for correct
stator wire connections.
NOTE: Apply Loctite 222 to the threads of the stator mounting screws.

b
b

51

a - Stator
b - Screw (M5 x 30) (3)
c - 2 pin connector

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

51 Loctite 222 92-809818 92-809818

Description Nm lb. in. lb. ft.

Stator screw 9.6 85

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Charging and Starting System

Voltage Regulator/Rectifier Removal/Installation

1. Disconnect the voltage regulator/rectifier wire connectors.
2. Remove the mounting screws and remove the voltage regulator/rectifier.
3. Reverse the steps for installation. Refer to the wiring diagram in Section 8 for correct
wire connections.
b

58979

a - Voltage regulator/rectifier
b - Screw (M6 x 40) (2)
c - Connectors

Description Nm lb. in. lb. ft.

Voltage regulator/rectifier mounting screw 8.5 75

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 Charging and Starting System

Starting System Components

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 the “START” position,
the starter solenoid is activated and completes the starting circuit between the battery and
the starter.
The neutral start switch opens the start circuit when the shift control lever is not in neutral.
This prevents accidental starting when the engine is in gear.
The starting system consists of the following components:
1. Battery
2. Starter solenoid
3. Neutral safety switch
4. Starter motor
5. Ignition switch

CAUTION
The starter motor may be damaged if operated continuously. Do not operate
continuously for more than 30 seconds. Allow a two 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 the battery is fully charged.
2. Check that the control lever is in the “NEUTRAL” position.
3. Check the battery terminals for corrosion and loose connections.
4. Check the starter solenoid and the starter for corrosion and loose connections.
5. Check the cables and the wiring for frayed and worn insulation.
6. Check the 20 ampere fuse.

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Charging and Starting System

Starter Solenoid Test

1. Inspect the starter solenoid for cracks, loose terminals or loose terminal lead
connections.
2. Connect the ohmmeter between the terminals of the starter solenoid.
3. Connect the black lead from the solenoid to the battery negative (–) terminal and
momentarily connect the brown lead to the positive (+) terminal of the battery.
4. Verify continuity between the starter solenoid terminals when 12 volts are applied.

b
a - Brown lead
b - Starter solenoid
c - Black lead
d - Battery

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 Charging and Starting System

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 the test points called out in the chart are numbered in the diagram
following.
Wire Color Abbreviations
BLK Black BLU Blue
BRN Brown GRY Grey
GRN Green ORN or ORG Orange
PNK Pink PPL or PUR Purple
RED Red TAN Tan
WHT White YEL Yellow
LT OR LIT Light DK or DRK Dark

Fuse Holder Assembly BRN YEL/RED

15 RED/PUR

YEL/RED
BRN
6

RED

BLK
BLK
Starter
3

YEL/RED
RED/PUR
BLK
(with
RED Sleeves) Diode
BLK Starter
(with Solenoid
Neutral
BLK

YEL Sleeves)
1 Start
Switch
7
4
5
2

+ – BLK
Ignition Switch
Battery

Starting Circuit Troubleshooting Flow Chart

Starter Motor Does Not Turn

SAFETY WARNING: Disconnect the black with yellow

sleeve starter motor cable from starter solenoid Test Point
1 before making Tests 1-thru-7 to prevent unexpected
engine cranking.

TEST 1
Set the ohmmeter to R x 1 scale and connect the meter leads
between the negative (–) battery post and the common power-
head ground.

No continuity indicated; there is an open circuit in the black Continuity Indicated

negative (–) battery cable between the negative (–) battery post Proceed to Test 2, on the next page.
and the powerhead.
• Check the cable for loose or corroded connections.
• Check the cable for open circuit.

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Charging and Starting System

* Battery Voltage
TEST 2
a. Disconnect the black ground wires from Test Point 2.
b. Connect the voltmeter between the common engine ground and Test Point 2.
No voltage reading; c. Turn the ignition key to the “Start” position.
proceed to Test 3.

TEST 3 12 Volt Reading*

a. Reconnect the black ground wires. Check the black ground wire for poor connection
b. Connect the voltmeter between the common engine ground and Test Point 3. or open circuit. Reconnect the ground wire to
c. Turn the ignition key to the “Start” position. starter solenoid; proceed to Test 7.

Electric Start Tiller Handle Model

No voltage reading; 12 Volt Reading
proceed to Test 4. Neutral start switch is open or the black leads are
Defective starter solenoid.
disconnected or damaged.

TEST 4
a. Connect the voltmeter between the com- 12 Volt Reading*
mon engine ground and Test Point 4. Neutral start switch is open, or the brown, or
No voltage reading; b. Turn the ignition key to the “Start” posi- yellow/red, or black wire is open between
proceed to Test 5. tion. Test Points 4 and 3. Check the diode adapter
if equipped.

TEST 5
Connect the voltmeter between the com- 12 Volt Reading*
No voltage reading; mon engine ground and Test Point 5. Defective ignition switch.
proceed to Test 6.

TEST 6
Connect the voltmeter between the common engine ground and Test Point 6.

No voltage reading; check the black with red

12 Volt Reading*
sleeve wire between the battery positive (+) Check the fuse in the red wire between Test Points 5 and 6.
terminal and Test Point 6. Check for the open red or red/purple wire between Test
Points 5 and 6.

TEST 7
a. Connect the voltmeter between the common engine ground and Test Point 1.
b. Turn the ignition key to the “Start” position.

No voltage reading; 12 Volt Reading*

defective starter solenoid. Should hear solenoid click; proceed to Test 8.

TEST 8
a. Reconnect the black with yellow sleeve cable to the starter solenoid Test Point 1.
b. Connect the voltmeter between the common engine ground and Test Point 7.
c. Turn the ignition key to “Start” position.

No voltage reading; check the black with 12 Volt Reading*

yellow sleeve cable for poor connection Check the black with yellow sleeve cable at the
or open circuit. starter for loose or corroded connection, or open
circuit. If the cable is OK, check the starter motor.

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 Charging and Starting System

Starter Motor Servicing

Removal
WARNING
Always disconnect the battery and remove the spark plug leads from the spark
plugs before working on the motor.
1. Disconnect the battery leads from the battery and the black starter motor lead from the
starter solenoid.
2. Remove the upper mounting screws and loosen the bottom screw. Lift the starter motor
in an upward direction and remove.

a 58980

a - Starter mounting screw (M8 x 45) (3)

b - Starter motor lead

Disassembly
1. Remove two thru-bolts and the commutator end cap. Do not lose the brush springs.
c
a b

a
c
a - Thru-bolts
b - Commutator end cap
c - Brush springs

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Charging and Starting System

2. Remove the nut, washer, spring, pinion stopper and pinion drive assembly. You may
need to lightly clamp the armature in a vise while removing the nut.
NOTE: Dispose of the nut after removing it. Use a new nut for reassembly.

e
c
b

c d
58223

a - Nut d - Spring
b - Washer e - Pinion
c - Pinion stopper (2)

3. Pull the armature from the starter frame.

f g h

d c d

a b e
a - Nut e - Pinion
b - Washer f - Drive end cap
c - Spring g - Armature shaft
d - Pinion stopper (2) h - Washer

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 Charging and Starting System

Cleaning and Inspection

1. Clean all the motor parts.
2. Check the pinion teeth for chips, cracks or excessive wear.
3. Replace the drive clutch spring and/or collar, if tension is not adequate, or if wear is
excessive.
4. Check that the brush holder is not damaged or is not holding the brushes against the
commutator.
5. Replace the brushes that are pitted or worn to less than 6.4 mm (1/4 in.) in length.
Refer to Brush Replacement, following.
6. Replace a damaged or excessively worn bushing in the end cap.
7. Check the armature commutator bar junction for a firm connection. A poor connection
usually results in a burned commutator bar.
8. Resurface and undercut a rough commutator, as follows:

CAUTION
Do not turn down the commutator excessively.
a. Resurface the commutator and undercut the insulation between the commutator
bars 0.8 mm (1/3 in.) to the full width of the insulation, make sure that the undercut
is flat.
b. Clean the commutator slots after undercutting.
c. De-burr the commutator lightly with No. 00 sandpaper, then clean the commutator.
d. Check the armature on a growler for shorts. Refer to Testing, following.
9. Open-circuited armatures often can be saved where an open circuit is obvious and
repairable. The most likely place for an open circuit is at the commutator bars. Long
cranking periods overheat the starter motor so that solder in the connections melts. The
poor connections cause arcing and burning of the commutator bars.
10. Repair bars, that are not too badly burned, by resoldering the leads in bars using rosin
flux solder and turning down the commutator in a lathe to remove burned material, then
undercut the mica.
11. Clean out the copper or brush dust from slots between the commutator bars.
12. Check the armature for shorts and ground. Refer to Testing following.

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Charging and Starting System

Testing

ARMATURE TEST FOR SHORTS

Check the armature for short circuits by placing on the growler and holding the hacksaw
blade over the armature core while the armature is rotated. If the saw blade vibrates, the
armature is shorted. Recheck after cleaning between the commutator bars. If the saw blade
still vibrates, replace the armature.

ARMATURE TEST FOR GROUND

1. Set the ohmmeter to R x 1 scale. Place one lead of the ohmmeter on the armature core
or shaft and the other lead on the commutator, as shown.
2. If the meter indicates continuity, the armature is grounded and must be replaced.

DMT Digital Multimeter Tachometer 91-892647A01

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 Charging and Starting System

CHECKING POSITIVE BRUSHES AND TERMINALS

1. Set the ohmmeter to R x 1 scale and connect the leads between the positive brushes.
2. The ohmmeter must indicate full continuity (zero resistance). If resistance is indicated,
check the lead to the positive terminal solder connection. If the connection cannot be
repaired, the brushes must be replaced. Refer to Brush Replacement.

11673

a - Positive brushes
DMT Digital Multimeter Tachometer 91-892647A01

TESTING NEGATIVE BRUSHES FOR GROUND

Set the ohmmeter to R x 1 scale. Place one lead of the ohmmeter on the negative brush and
the other lead on the end cap bare metal. If the meter indicates no continuity, replace the
negative brush. Repeat this procedure on the other negative brush.

b
a

a - Negative (–) brushes

b - End cap
DMT Digital Multimeter Tachometer 91-892647A01

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Charging and Starting System

Brush Replacement
IMPORTANT: Replace brushes that are pitted or worn to less than 6.4 mm (1/4 in.)
in length.

e
c
f
g

b
a

a - Positive (+) terminal

b - Long brush lead
c - Push lead into slot
d - Insulating washer
e - Flat washer
f - Lock washer
g - Nut

a c b

b a

a - Positive (+) brushes (2)

b - Negative (–) brushes (2)
c - Brush holder
d - Bolts – Fasten negative brushes and card

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 Charging and Starting System

Reassembly
1. Lubricate the helix threads and the drive end cap bushing with SAE 10W oil.
2. Install the pinion, pinion stopper, spring, second pinion stopper, washer, and the new nut
onto armature shaft.
3. Lightly clamp the armature in a vise and torque the nut to the specified torque.

f g h

d c d

a e
b
a - Nut
b - Washer
c - Spring
d - Pinion stopper (2)
e - Pinion
f - Drive end cap
g - Armature shaft
h - Washer

Description Nm lb. in. lb. ft.

Starter shaft nut 30.5 22.5

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Charging and Starting System

4. Construct a brush retainer tool as shown.

Brush Retainer Tool Layout (Full Size)

18-Gauge Sheet Metal

Metric scale
76.2 mm = 3 in.
50.8 mm = 2 in.
44.5 mm = 1-3/4 in.
42.9 mm = 1-11/16 in.
19.1 mm = 3/4 in.
12.7 mm = 1/2 in.

Brush Retainer Tool Side View (Full Size)

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 Charging and Starting System

5. Place the springs and the brushes into the brush holder and hold in place with the brush
retainer tool.
6. Lubricate the bushing with one drop of SAE 10W oil. Do not over-lubricate.
a

a - Brush retainer tool

b - Bushing

7. Position the armature into the starter frame so that the commutator end of the armature
is at the end of the starter frame where the permanent magnets are recessed 25.4 mm
(1 in.). Align the marks as shown.
8. Install the commutator end cap onto the starter frame. Align the marks as shown, and
remove the brush retainer tool.
9. Install the thru-bolts. Tighten to the specified torque.

a - Alignment the marks at the end of the starter frame

b - Alignment the marks at the commutator end cap
c - Thru-bolts (2)

Description Nm lb. in. lb. ft.

Starter motor thru-bolt 7.9 70

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Charging and Starting System

Installation
1. Secure the starter to the block with three mounting screws. Tighten the screws to the
specified torque. Secure the starter motor lead as shown.

a 58980

a - Starter mounting screw (M8 x 45) (3)

b - Starter motor lead
Description Nm lb. in. lb. ft.
Starter motor mounting screw 29 22

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 Timing, Synchronizing, and Adjusting

Electrical
Section 2C - Timing, Synchronizing, and Adjusting
Table of Contents
2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Maximum Throttle . . . . . . . . . . . . . . . . . . . 2C-6
C
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-7
Throttle Link Setting . . . . . . . . . . . . . . . . . . . . 2C-5 Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-8
Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-5 Throttle Position Sensor (TPS) . . . . . . . . . . . 2C-8

90-883064R02 JULY 2006 Page 2C-1

Timing, Synchronizing, and Adjusting

Special Tools
1. DMT 2000 Digital Multimeter Tachometer P/N 91-892647A01

2. Timing Light P/N 91-99379

3. Digital Diagnostic Tester P/N 91-823686A2

4. DDT Cartridge 91-880118A04 and DDT Reference Manual P/N 90-881204003

Page 2C-2 90-883064R02 JULY 2006

 Timing, Synchronizing, and Adjusting

5. DDT Cable 10’ (3.05 m) Extension P/N 84-825003A1

6. DDT Test Harness P/N 84-822560A5

7. Computer Diagnostic System

NOTE: For additional information, pricing, or to order the Computer Diagnostic
System contact: SPX Corporation, 28635 Mound Rd., Warren MI 48092 or call: USA
1-800-345-2233, Canada 800-345-2233, Europe 49 6182 959 149, or Australia (03)
9544-6222.

4520

90-883064R02 JULY 2006 Page 2C-3

Timing, Synchronizing, and Adjusting

Specifications
Type Capacitor Discharge Ignition
Spark Plug:
Type Champion RA8HC
Gap 1.0 mm (0.040 in.)
Hex Size 16 mm (5/8 in.)
Torque 17 Nm (150 lb. in.)
Hole Size 12 mm
Firing Order 1-2-3
Ignition Timing:
@ Idle Controlled by ECM
@ 1800 - 2000 17° B.T.D.C.
@ WOT (6000 RPM) 28° B.T.D.C.
Stator Resistance 0.20 - 0.30 Ω (yellow - yellow)
Crank Position Sensor (CPS)
Resistance 300 - 350 Ω (red - white)
Ignition Coil Resistance:
0T979999 And Below
Internal Shielding 0 - 10.0 kΩ (Pin A - mounting bracket)
Electronic Spark Trigger (EST) 8.5 - 12 kΩ (Pin B - Pin C)
Secondary 3.0 - 7.0 kΩ (Pin A - coil tower)
Ignition High Tension Lead/Boot
System Resistance 0.600 - 1.100 kΩ
Readings taken @ 0T980000 And Up
20° C (68° F) Primary 0.25 Ω ± 10% (Pin D - Pin E)
Secondary 1.0 kΩ ± 20% (Pin C and coil tower)
Electronic Spark Trigger (EST) 8.5 - 12 kΩ (Pin A - Pin B)
ECM Engine RPM Limiter
Fuel/Spark Cutout On Cylinder #2 6225 RPM
Fuel/Spark Cutout On All Cylinders 6350 RPM
ECM Overheat RPM Control Guardian is active. Power limit will vary with level
of overheat.
ECM Low Oil Pressure RPM Control Guardian is active. Engine power is limited to 10%
of maximum (approximately 2000 RPM).
See Graph in Section 3B - EFI
MAT/ECT Temperature Sensor See Table in Section 3B - EFI
Manifold Absolute Pressure (MAP)
Sensor Resistance 10.0 - 13.5 Ω
Fuel Injector Resistance 81 - 99 Ω (Pin 85 - Pin 86)
Main Power Relay 24 - 30 Ω between pins
Idle Air Control (IAC)
Throttle Position Sensor Range 0.39 - 1.00 volts
Output Voltage @ Idle 3.66 - 4.80 volts
Output Voltage @ WOT

NOTE: The 30/40 EFI (4-Stroke) ECM controls the ignition timing electronically.
Therefore, making the ignition timing non-adjustable. When initially running the
outboard, use a timing light to verify that the ignition timing falls within the timing windows
outlined in this section.

Page 2C-4 90-883064R02 JULY 2006

 Timing, Synchronizing, and Adjusting

Throttle Link Setting

Idle
NOTE: For remote control models, remove remote control throttle cable during throttle link
adjustment. For tiller handle models, throttle cables remain attached and throttle twist grip
should be used to advance throttle during throttle link adjustment.
1. Lightly hold throttle body arm against idle stop.
2. Slowly push throttle lever forward until you feel the throttle body arm start to move. The
center of throttle arm timing mark should line up with the throttle cam timing mark.
3. If adjustment is needed, refer to Section 7A - Throttle Link Adjustment.

c d
e

a
b

a - Throttle body arm

b - Throttle lever
c - Throttle timing marks
d - Timing marks properly aligned
e - Shorten link rod

90-883064R02 JULY 2006 Page 2C-5

Timing, Synchronizing, and Adjusting

Maximum Throttle
1. With throttle cables attached, advance throttle to wide open throttle position.
2. Throttle stop should lightly contact adjoining surface. To ensure the throttle shutter is
fully open, back the throttle stop screw out until there is a gap between the throttle stop
screw and adjoining surface at WOT position. Keep turning the throttle stop screw in until
the throttle stop lightly contacts the adjoining surface.

a - Throttle lever
b - Throttle stop screw
c - Throttle stop

Page 2C-6 90-883064R02 JULY 2006

 Timing, Synchronizing, and Adjusting

Timing
WARNING
To prevent personal injury or possible death, from loss of balance or stability while
servicing the motor, do not attempt to check timing while the boat is in motion.
Failure to follow one of the recommended servicing procedures may result in the
person falling overboard or causing personal injury from falling in the boat.

WARNING
To prevent personal injury from the spinning flywheel, do not attempt to remove the
flywheel cover or place hands on top of the cover when checking the ignition timing.
Ignition timing is not adjustable. The Electronic Control Module (ECM) unit electronically
controls the ignition timing.
When initially running the outboard, use a timing light to verify that the ignition timing falls
within the timing windows as described within the following tests.
IMPORTANT: When checking the timing with the engine running, one of the following
test procedures must be followed.
Check maximum timing per specification while running the outboard:
• In a test tank
• On a dynamometer
• On a boat secured on a trailer in water
1. Attach timing light to #1 spark plug lead.

Timing Light 91-99379

a c

58985

a - Timing light clamp

b - #1 spark plug lead
c - Timing window - electric start models

90-883064R02 JULY 2006 Page 2C-7

Timing, Synchronizing, and Adjusting

NOTE: Idle timing is controlled by the ECM and will vary for idle speed control. Checking
the ignition timing marks using a timing light will not be stable until 1800 - 2000 RPM.
2. Start the engine and place the outboard in forward gear. Check timing at 1800 - 2000
RPM, timing should be 17° BTDC. If timing is not within specification, refer to Section
3B - EFI Troubleshooting and Diagnostics.

a
17° BTDC

15

a - Timing mark @ 1800-2000 RPM

Timing specification
1800 - 2000 RPM 17° BTDC

3. Slowly increase the engine RPM while watching the ignition timing marks. The timing
should increase to the maximum timing specification at approximately 6000 RPM. If not
within specification window, refer to Section 3B - EFI Troubleshooting and
Diagnostics.

a
28° BTDC

a - Timing mark @ full advance

Timing specification
Full throttle advance 28° BTDC

Idle Speed
Engine idle speed is maintained by the ECM and is therefore not adjustable. The
parameters affecting the idle speed can be checked and monitored using the Digital
Diagnostic Terminal (DDT). Refer to Section 3B - EFI Troubleshooting and Diagnostics.

Throttle Position Sensor (TPS)

The Throttle Position Sensor (TPS) is not adjustable. TPS voltage reading can be monitored
with the DDT through the ECM. If readings are not within specifications, refer to Section
3B - EFI Troubleshooting and Diagnostics.

Page 2C-8 90-883064R02 JULY 2006

 Theory of Operation

Electronic Fuel Injection

Section 3A - Theory of Operation

Table of Contents
Electronic Fuel Injection System . . . . . . . . . . . 3A-2 Manifold Air Temperature (MAT) Sensor . 3A-9
Air Induction System . . . . . . . . . . . . . . . . . . 3A-2 Throttle Position Sensor (TPS) . . . . . . . . . 3A-9
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System Components . . . . . . . . . . . . . . . .
3A-3
3A-5
Oil Pressure Switch . . . . . . . . . . . . . . . . . . .
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3A-9
3A-10
3
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-5 Idle Air Control (IAC) . . . . . . . . . . . . . . . . . . 3A-10 A
Vapor Separator . . . . . . . . . . . . . . . . . . . . . . 3A-6 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . 3A-10
Fuel Pressure Regulator . . . . . . . . . . . . . . 3A-7 Main Power Relay . . . . . . . . . . . . . . . . . . . . . . . 3A-11
Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-8 Fuse Holder Assembly . . . . . . . . . . . . . . . . . . . 3A-11
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-8 Suppression Diode . . . . . . . . . . . . . . . . . . . . . . 3A-12
Crank Position Sensor (CPS) . . . . . . . . . . 3A-8 Electronic Control Module (ECM) . . . . . . . . . . 3A-12
Engine Coolant Temperature Electronic Control Module Functions . . . . 3A-13
(ECT) Sensor . . . . . . . . . . . . . . . . . . . . . . . 3A-9 Outline of Control System . . . . . . . . . . . . . 3A-14
Manifold Absolute Pressure Control and Function . . . . . . . . . . . . . . . . . . 3A-15
(MAP) Sensor . . . . . . . . . . . . . . . . . . . . . . . 3A-9

90-883064R02 JULY 2006 Page 3A-1

Theory of Operation

Electronic Fuel Injection System

Air Induction System
The air induction system consists of an intake manifold with an intake runner for each
cylinder joined to a common air box, a single throttle body/shutter with attached Throttle
Position Sensor (TPS), an Idle Air Control (IAC), a Manifold Absolute Pressure (MAP)
sensor, and a Manifold Air Temperature (MAT) sensor. The intake manifold also mounts
the fuel distribution manifold and the fuel injectors.

a c
f

a - Intake manifold
b - Throttle body/shutter
c - Throttle Position Sensor (TPS)
d - Idle Air Control (IAC)
e - Manifold Absolute Pressure (MAP) sensor
f - Manifold Air Temperature (MAT) sensor

Page 3A-2 90-883064R02 JULY 2006

 Theory of Operation

Fuel System
The fuel system consists of a fuel line connector, a water separating fuel filter, a
low-pressure mechanical fuel pump, a high-pressure electric fuel pump, a fuel distribution
manifold, fuel injectors, a fuel cooler and a fuel pressure regulator. The low-pressure
mechanical fuel pump draws fuel from the fuel tank through the fuel line connector and fuel
filter, then delivers it to the high-pressure fuel pump within the vapor separator tank.
High-pressure fuel is circulated through the fuel cooler and supplied to the fuel distribution
manifold and fuel injectors to be sprayed into the intake manifold. Unused fuel circulates
through the fuel cooler, then flows through the pressure regulator, and returns to the vapor
separator tank.
SERIAL NUMBER 1B036613 AND BELOW

h f
a e

a - Fuel line connector

b - Water separating fuel filter
c - Low-pressure mechanical fuel pump
d - Vapor separator tank/high-pressure electric fuel pump
e - Fuel cooler
f - Fuel distribution manifold
g - Fuel injectors (3)
h - Pressure regulator
i - High-pressure fuel filter

90-883064R02 JULY 2006 Page 3A-3

Theory of Operation

SERIAL NUMBER 1B036614 AND UP

f
e
a

g
a - Fuel line connector
b - Water separating fuel filter
c - Low-pressure mechanical fuel pump
d - Vapor separator tank/high-pressure electric fuel pump
e - Fuel cooler
f - Fuel distribution manifold
g - Fuel injectors (3)
h - High-pressure fuel filter

Page 3A-4 90-883064R02 JULY 2006

 Theory of Operation

Fuel System Components

Fuel Pump
The fuel pump is a diaphragm pump which is mechanically driven off of the camshaft.
The pump base insulates the fuel pump from the heat of the engine block. The fuel pump
is water-cooled to help prevent vapor lock.
If the engine runs out of fuel, or has a restriction on the inlet side of the pump preventing
adequate fuel flow, the pump will make a clicking noise.

c
b

d
a - Fuel from the filter/tank
b - Fuel outlet to the VST
c - Water inlet from the VST fuel cooler
d - Water outlet to the tell-tale

90-883064R02 JULY 2006 Page 3A-5

Theory of Operation

Vapor Separator
SERIAL NUMBER 1B036613 AND BELOW
The vapor separator maintains a liquid fuel supply for the high-pressure fuel pump located
in the vapor separator tank. Fuel delivered from the mechanical low-pressure fuel pump is
supplied to the top of the vapor separator and is controlled by the inlet needle/float
assembly. Pressurized fuel from the high-pressure pump circulates through the fuel
cooler, to the fuel distribution manifold and injectors. Excess fuel flows through the
pressure regulator back to the vapor separator tank.

a e a
e

d b
d

c
f
f

a - Fuel from the mechanical fuel pump

b - Inlet needle and float valve
c - High-pressure electric fuel pump
d - Fuel cooler
e - Pressure regulator
f - Fuel outlet to the fuel distribution manifold

Page 3A-6 90-883064R02 JULY 2006

 Theory of Operation

SERIAL NUMBER 1B036613 AND UP

h
a i
a
g
g
f
b
f
e
e
d
c
d

8292

a - Fuel inlet from the mechanical fuel pump

b - Inlet needle
c - High-pressure fuel pump
d - High-pressure fuel to the fuel distribution manifold
e - Fuel cooler
f - Fuel line from the high-pressure pump to the fuel cooler
g - Fuel line from the fuel cooler to the fuel pressure regulator
h - VST vent to the intake manifold
i - Fuel pressure regulator
Fuel Pressure Regulator
SERIAL NUMBER 1B036613 AND BELOW
The fuel pressure regulator mounted on top of the vapor separator maintains a stable fuel
pressure between the high-pressure fuel pump and the fuel injectors. The pressure
regulator consists of a spring-loaded diaphragm which actuates a valve/seat assembly.
Excess fuel pressure unseats the valve returning fuel to the vapor separator tank. The
excess fuel is channeled below the fuel level in the vapor separator tank through an
internal pipe to prevent fuel vaporization.
The spring side of the diaphragm is vented to the atmosphere allowing barometric
conditions to act on the diaphragm in addition to the spring pressure.

c
a - Vent to the atmosphere
b - High-pressure fuel from the fuel cooler
c - Excess fuel flows to the VST

90-883064R02 JULY 2006 Page 3A-7

Theory of Operation

SERIAL NUMBER 1B036613 AND UP

The fuel pressure regulator is mounted inside the VST on the vapor separator cover and
maintains a stable fuel pressure between the high-pressure fuel pump and the fuel
injectors. The pressure regulator consists of a spring-loaded diaphragm which actuates a
valve/seat assembly. Excess fuel pressure unseats the valve returning fuel to the vapor
separator tank. The excess fuel is channeled below the fuel level in the vapor separator
tank through an internal pipe to prevent fuel vaporization.
The spring side of the diaphragm is vented inside the VST tank. The VST tank is vented to
the atmospheric pressure allowing barometric pressure changes to act on the diaphragm
in addition to the spring pressure.

Fuel Cooler
A heat exchanging fuel cooler is attached to the vapor separator tank. The fuel cooler uses
engine cooling water to reduce the temperature of the high-pressure fuel supply to the fuel
injectors and fuel returned to the VST through the fuel pressure regulator. Removing heat
from the circulating high-pressure fuel prevents the formation of fuel vapors reducing the
possibility of vapor lock.

Sensors
Sensors send input signals to the ECM regarding engine operating conditions.

Crank Position Sensor (CPS)

As the flywheel rotates, the CPS senses the location of the 54 teeth on the flywheel. The
ECM utilizes the CPS information and determines when to trigger each ignition coil and
fuel injector.
The CPS provides the ECM with crank angle position and engine speed information, which
the ECM uses in determining fuel delivery and spark timing.

Page 3A-8 90-883064R02 JULY 2006

 Theory of Operation

Engine Coolant Temperature (ECT) Sensor

The ECT sensor is located on the engine’s exhaust cover and protrudes into the return
water passage. The sensor monitors the temperature of the cooling water that has passed
through the engine as controlled by the thermostat and sends signals to the ECM for
processing. The ECM calculates the optimum fuel injection pulse width based on the
digital information of the ECT.

Manifold Absolute Pressure (MAP) Sensor

The MAP sensor is mounted into the intake manifold, and measures the absolute
pressure within the intake manifold. This information is then used to calculate fuel delivery
and spark timing.

Manifold Air Temperature (MAT) Sensor

The MAT sensor is mounted into the intake manifold and measures the charged air
temperature. The ECM calculates the optimum fuel injection pulse width based on the
digital information of the MAT sensor.

Throttle Position Sensor (TPS)

The TPS sensor is located on the throttle body and is connected to the throttle shaft. It
provides the ECM with throttle angle information.

Oil Pressure Switch

The oil pressure switch is located port side of the engine and protrudes into the oil galley
between the oil pump and the oil filter. The sensor sends a low oil pressure signal to the
ECM, which activates the ignition/injection cutoff and warning horn.

90-883064R02 JULY 2006 Page 3A-9

Theory of Operation

Actuators
Actuators receive input signals from the ECM, which control air-fuel ratios, spark advance,
and idle RPM.

Idle Air Control (IAC)

The IAC is an electrically operated spring-loaded solenoid valve, which controls the
amount of intake air that bypasses the closed throttle shutter. Signals from the ECM
regulate the duty cycle that the IAC valve remains open. Duty cycle of the IAC valve ranges
from 0% to 100% open. The IAC controls three operating functions:
1. Provides additional intake air bypass for engine start-up and allows increased idle
RPM during engine warm-up.
2. Controls idle speed according to varying engine loads and running conditions.
3. Functions as an electronic dashpot by providing additional bypass air as the throttle
quickly closes during a rapid deceleration, preventing engine stalling.

Fuel Injector
The fuel injector is an electrically operated spring-loaded solenoid, which delivers a
metered amount of fuel into the intake manifold runner, just ahead of the intake valve. The
injectors are electrically charged as the key switch is set to the “RUN” position. The ECM
controls the injection by completing the ground circuit, lifting the solenoid, which allows
high-pressure fuel to flow. The ECM then opens the ground circuit allowing the spring to
close the injector and stop the fuel flow.

Page 3A-10 90-883064R02 JULY 2006

 Theory of Operation

Main Power Relay

The main power relay is controlled by the ECM. It provides power to the ignition coils, idle
air control, injectors, and high-pressure fuel pump.

Fuse Holder Assembly

The fuse holder holds four function fuses and one spare fuse.
1. Fuse number one protects the SmartCraft wiring.
2. Fuse number two is powered by the main relay. It protects the red/blue leads on the
engine. This fuse provides power to the injectors, the idle air control, and the electric
fuel pump.
3. Fuse number three protects the red/purple leads on the engine, the main power relay,
and the key switch. When the key switch is on, the purple leads on the engine, the key
switch and the dash gauges are also powered/protected through this fuse.
4. Fuse number four is powered by the main relay. It protects the red/yellow leads on the
engine. This fuse provides power to the ignition coils.
5. Fuse number 5 is a spare 20 ampere fuse.

5
1 3

15

2 4

58858

90-883064R02 JULY 2006 Page 3A-11

Theory of Operation

Suppression Diode
The suppression diode is located between the brown start solenoid lead and the
yellow/red key switch lead (within the engine harness), and connects to the engine
ground. The purpose of the suppression diode is to eliminate the inductive spike created
as the start solenoid is de-energized (key switch turned from “START” to “RUN”). If the
battery leads were connected in reverse polarity, the diode will short to ground and blow
the power relay fuse.

Electronic Control Module (ECM)

The ECM is designed to operate within the variables of a 12 volt DC system. It is important
to use a fully charged battery. If the ECM should fail, the engine will stop running.
The inputs to the ECM can be monitored and tested by the DDT or Computer Diagnostic
System (CDS).
The ECM performs the following functions:
• Calculates the precise fuel and ignition timing requirements based on engine
speed, throttle position, manifold pressure, manifold air temperature and engine
coolant temperature
• Directly controls the ground circuit of fuel injectors, ignition coils, and idle air control
• Indirectly controls the positive circuit of fuel injectors, ignition coils, and idle air con-
trol through the main relay
• Controls alarm horn and warning functions
• Controls RPM limit function
• Records engine running information

Page 3A-12 90-883064R02 JULY 2006

 Theory of Operation

Electronic Control Module Functions

Crank Position Sensor Fuel pump
(CPS)

Throttle Position
Fuel injectors
Sensor (TPS)

Engine Coolant Temperature Idle Air Control (IAC)

(ECT) sensor

Manifold Air Temperature

ECM Ignition coils

(MAT) sensor (Electronic

SmartCraft output
Control
Manifold Absolute
Pressure (MAP) sensor Module) Computer Diagnostic System (CDS)
Digital Diagnostic Terminal (DDT)

Oil pressure switch

Warning horn
Ignition key switch

Tachometer

90-883064R02 JULY 2006 Page 3A-13

Theory of Operation

Outline of Control System

ECM Sensors

Ignition Timing 0 Engine load / Engine speed map Manifold Absolute Pressure (MAP) sensor
Control Crank Position Sensor (CPS)
Manifold Air Temperature (MAT) sensor

0 Engine temperature correction Engine Coolant Temperature (ECT) sensor

0 Starting correction Engine Coolant Temperature (ECT) sensor

Crank Position Sensor (CPS)

0 Ignition cutoff for decreased engine speed Crank Position Sensor (CPS)
Engine Coolant Temperature (ECT) sensor
Oil pressure switch

0 Over-revolution prevention Crank Position Sensor (CPS)

0 Engine cutoff Ignition key switch

Stop switch
0 Idling stabilizer Crank Position Sensor (CPS)

0 Safety control Sensors and switches

ECM Sensors

Fuel system 0 Engine load / Engine speed map Manifold Absolute Pressure (MAP) sensor
Manifold Air Temperature (MAT) sensor

0 Engine temperature correction Engine Coolant Temperature (ECT) sensor

0 Starting correction Engine Coolant Temperature (ECT) sensor

0 Rapid acceleration correction Throttle Position Sensor (TPS)
Crank Position Sensor (CPS)
0 Rapid deceleration correction Throttle Position Sensor (TPS)
Crank Position Sensor (CPS)

0 Fuel cutoff for decreased engine speed Crank Position Sensor (CPS)
Oil pressure switch
Engine Coolant Temperature (ECT) sensor
Battery voltage
0 Over-revolution prevention Crank Position Sensor (CPS)

0 Safety control Sensors and switches

Page 3A-14 90-883064R02 JULY 2006

 Theory of Operation

ECM Sensors
IAC Control 0 Engine speed Crank Position Sensor (CPS)

0 Engine temperature correction Engine Coolant Temperature (ECT) sensor

Crank Position Sensor (CPS)
Throttle Position Sensor (TPS)
0 Starting correction Engine Coolant Temperature (ECT) sensor

0 Rapid deceleration correction Throttle Position Sensor (TPS)

Crank Position Sensor (CPS)
0 Idling speed feedback Crank Position Sensor (CPS)
Engine Coolant Temperature (ECT) sensor
0 Variable idling speed control Throttle Position Sensor (TPS)
Crank Position Sensor (CPS)
0 Starting preparation Engine Coolant Temperature (ECT) sensor
0 Safety control Sensors and switches

Control and Function

Ignition Fuel IAC Function

Crank Position Sensor f f f Detects the crankshaft posi-

(CPS) tion and engine speed
Throttle Position Sensor f f f Detects the open degree of
(TPS) the throttle valve
Engine Coolant Temperature f f f Detects engine temperature
(ECT) sensor
Manifold Absolute Pressure f f Detects intake air pressure
(MAP) sensor of the intake manifold
Manifold Air Temperature f f Detects intake air
(MAT) sensor temperature
Oil pressure switch f f Detects oil pressure

90-883064R02 JULY 2006 Page 3A-15

 Troubleshooting and Diagnostics

Electronic Fuel Injection

Section 3B - Troubleshooting and Diagnostics

Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Troubleshooting Without Digital Diagnostic
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-4 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-15
EFI System Diagnostic Procedures . . . . . . .
Pressure Regulator Test . . . . . . . . . . . . . .
3B-5
3B-5
Guardian Protection System . . . . . . . . . .
EFI System Troubleshooting Guide . . . .
3B-15
3B-17
3
Mechanical Fuel Pump Test . . . . . . . . . . . . . . 3B-6 Component Resistance Tests . . . . . . . . . . . . 3B-21 B
Checking for Restricted Fuel Flow Caused by Engine Coolant Temperature (ECT)
Anti-Siphon Valves . . . . . . . . . . . . . . . . . . 3B-6 Sensor and Manifold Air Temperature
Vacuum (Lift) Test . . . . . . . . . . . . . . . . . . . 3B-6 (MAT) Sensor . . . . . . . . . . . . . . . . . . . . . . 3B-21
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 3B-9 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . 3B-22
EFI System Troubleshooting . . . . . . . . . . . . . 3B-11 Main Power Relay . . . . . . . . . . . . . . . . . . . 3B-22
Using the Digital Diagnostic Terminal Manifold Absolute Pressure (MAP)
(DDT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-11 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-23
DDT Functions - 4-Stroke EFI Models . . . . . 3B-13 Crank Position Sensor . . . . . . . . . . . . . . . 3B-23

90-883064R02 JULY 2006 Page 3B-1

Troubleshooting and Diagnostics

Special Tools
1. Fuel Pressure Gauge

a
b

a - 91-881833A03
b - 91-881834A1

2. DMT 2000 Digital Multimeter Tachometer P/N 91-892647A01

3. Cartridge P/N 91-880118A04

Page 3B-2 90-883064R02 JULY 2006

 Troubleshooting and Diagnostics

4. Digital Diagnostic Tester P/N 91-823686A2

5. DDT Technical Manual P/N 90-881204003

6. DDT Cable 3.05 m (10 ft.) Extension P/N 84-825003A1

7. DDT Test Harness P/N 84-822560A5

90-883064R02 JULY 2006 Page 3B-3

Troubleshooting and Diagnostics

8. Computer Diagnostic System

NOTE: For additional information, pricing, or to order the Computer Diagnostic
System contact: SPX Corporation, 28635 Mound Rd., Warren MI 48092 or call:
USA 1-800-345-2233, Canada 800-345-2233, Europe 49 6182 959 149, or Australia
(03) 9544-6222.

4520

Specifications

Fuel Pump Type Mechanical Water Cooled

(Plunger/Diaphragm)
Fuel
Fuel Pump:
System
Pressure 20.7 - 41 kPa (3 - 6 PSI)
Fuel Tank Capacity Accessory
Fuel Injector System Batch
Idle RPM (Out Of Gear) 775 ± 25 RPM
Idle RPM (In Forward Gear) 775 ± 25 RPM
Fuel Injection
Wide Open Throttle RPM (WOT)
Range 5500 - 6000
Fuel Pump Pressure - Electric 290 - 303 kPa (42 - 44 PSI)

Page 3B-4 90-883064R02 JULY 2006

 Troubleshooting and Diagnostics

EFI System Diagnostic Procedures

Pressure Regulator Test
1. Install the fuel pressure gauge onto the pressure check valve located on the VST.
2. Start the engine. Fuel pressure should be within specification.

91-16850A7
c

a - Fuel pressure gauge

b - Pressure relief button
c - Drain hose

Fuel Pressure Gauge 91-16850A7

Fuel pressure check

Fuel pressure 290 - 303 kPa (42 - 44 PSI)

90-883064R02 JULY 2006 Page 3B-5

Troubleshooting and Diagnostics

Mechanical Fuel Pump Test

Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves
While anti-siphon valves may be helpful from a safety standpoint, they clog with debris,
they may be too small, or they may have too heavy a spring. The pressure drop across
these valves can create operational problems and/or powerhead damage by restricting the
fuel to the fuel pump and the VST. Some symptoms of restricted fuel flow, which could be
caused by use of an anti-siphon valve, are:
1 - Loss of fuel pump pressure
2 - Loss of power
3 - High speed surging
4 - Pre-ignition/detonation (piston dome erosion)
5 - Outboard cuts out or hesitates upon acceleration
6 - Outboard runs rough
7 - Outboard quits and cannot be restarted
8 - Outboard will not start
9 - Vapor lock
Since any type of anti-siphon device must be located between the outboard fuel inlet and
fuel tank outlet, a simple method of checking if such a device or bad fuel is a problem
source, is to operate the outboard with a remote fuel tank which is known to be good.
After using a separate fuel supply, and it is found that the anti-siphon valve is the cause
of the problem, there are 2 solutions to the problem; either 1) replace the anti-siphon valve
with one that has a lighter spring tension or 2) replace it with a solenoid-operated fuel shut
off valve.
Vacuum (Lift) Test
Fuel system vacuum can be checked using a short piece of extra fuel hose, a vacuum
gauge, and a T fitting.
1. Conduct test with water to the engine cooling system using one of the following methods:
• In a test tank
• With boat/outboard lower unit in the water
2. Disconnect the fuel hose from the inlet fitting of the mechanical fuel pump.
3. Connect an extra fuel hose onto the inlet fitting of the pump.
4. Install the T fitting into the extra hose making connection as close to the pump as
possible.
5. Connect the vacuum gauge and the fuel inlet hose onto the T fitting.
6. Start the engine and run at 1000 RPM. The fuel system vacuum lift should be to
specifications.
NOTE: The system vacuum test is normally performed at 1000 RPM. As engine RPM is
increased, there will be a slight increase in the vacuum. This increase should not exceed
the specifications.

Fuel system vacuum lift

@ 1000 RPM 25 - 50 mm Hg (1 - 2 in. Hg)

Page 3B-6 90-883064R02 JULY 2006

 Troubleshooting and Diagnostics

7. To isolate the mechanical fuel pump from the rest of the fuel system:
a. Pinch off/restrict the fuel supply hose between the vacuum gauge and the fuel tank.
b. The mechanical fuel pump vacuum lift should be to specifications.
c. If the vacuum reading for the pump is below specifications, the pump needs
rebuilding.

Mechanical fuel pump vacuum lift

@ 1000 RPM 101.6 mm Hg (4 in. Hg)

8. If the vacuum reading is not within specifications, refer to the Vacuum Lift
Troubleshooting table.
9. Stop the engine, remove the gauge, and reconnect the fuel line to the inlet fitting of the
fuel pump.
The fuel pump is designed to lift fuel vertically about 1524 mm (60 in.), if there are no other
restrictions in the system, using a fuel hose that is 7.9 mm (5/16 in.) minimum in diameter.
As restrictions are added, such as filters, fittings, valves, etc., the amount of fuel pump lift
decreases.

d
a
b
57859

a - Extra hose to the inlet fitting of the mechanical fuel pump

b - T fitting
c - Vacuum gauge
d - Fuel supply hose from the fuel tank

90-883064R02 JULY 2006 Page 3B-7

Troubleshooting and Diagnostics

Vacuum Lift Troubleshooting

Condition Cause Correction
Fuel system vacuum lift above Restricted anti-siphon valve Refer to Checking for
specification Restricted Fuel Flow Caused
by Anti-Siphon Valves
preceding
Plugged fuel tank pick-up screen Clean/replace fuel pick-up
screen
Pinched/collapsed fuel hose Inspect/replace fuel hoses
Dirty/plugged water separating Clean/replace water separating
fuel filter fuel filter
Restriction in fuel line thru-hull Clean/replace fitting
fitting
Restriction in fuel tank switching Clean/replace valve
valve
Restriction within primer bulb Rebuild/replace primer bulb
Fuel system vacuum lift below Low fuel level in fuel tank Fill tank with fuel
specifications
ifi ti Hole/cut in pick-up tube of fuel Replace fuel pick-up tube
tank
Loose fuel line connection Check/tighten all connections
Hole/cut in fuel line Inspect/replace fuel hoses
Loose fuel pump screws Torque screws to specification
Fuel pump gaskets worn or leak- Rebuild/replace fuel pump
ing
Fuel pump check valves/seals Rebuild/replace fuel pump
leaking
Leaky fuel pump diaphragm Rebuild/replace fuel pump
Worn/broken fuel pump springs Rebuild/replace fuel pump
Leaky fuel pump seals Rebuild/replace fuel pump
Fuel filter bowl loose Tighten fuel filter bowl
Fuel filter gasket cut/worn Replace gasket
Fuel vaporization Check for plugged fuel pump
water cooling circuit

Page 3B-8 90-883064R02 JULY 2006

 Troubleshooting and Diagnostics

Pressure Test
Fuel system pressure troubleshooting can be performed using a piece of clear fuel hose
10 cm (4 in.) long, a pressure gauge, and a T fitting.
1. Conduct test with water to the engine cooling system using one of the following methods:
• In a test tank
• With boat/outboard lower unit in the water
2. Disconnect the fuel hose from the outlet fitting of the mechanical fuel pump.
3. Connect a clear fuel hose onto the inlet fitting of the pump.
4. Install the T fitting onto a clear fuel hose.
5. Connect the pressure gauge and the fuel outlet hose to the VST, onto the T fitting.
6. Start the engine and run at 1000 RPM. The fuel system pressure should be to
specifications.

Fuel system pressure

@ 1000 RPM Pressure should exceed 13.7 kPa (2 PSI)

7. To isolate the mechanical fuel pump from the rest of the fuel system:
a. Pinch off/restrict the fuel hose between the T fitting and the VST.
b. The mechanical fuel pump pressure should be to specifications.
c. If the pressure reading for the pump is below specifications, the pump needs
rebuilding.

Mechanical fuel pump pressure

@ 1000 RPM Pressure should exceed 20.7 kPa (3 PSI)

8. If the fuel pressure reading is below specifications, refer to the Fuel Pressure
Troubleshooting table.
9. Stop the engine, remove the gauge/clear hoses and reconnect the fuel line to the outlet
fitting of the fuel pump.

b a

a - Clear hose from the mechanical fuel pump outlet to the T fitting
b - T fitting
c - Fuel pressure gauge
d - Fuel hose to the VST

Fuel Pressure Gauge 91-16850A7

90-883064R02 JULY 2006 Page 3B-9

Troubleshooting and Diagnostics

Fuel Pressure Troubleshooting

Condition Cause Correction
Fuel system pressure below Restricted anti-siphon valve Refer to Checking for
specification Restricted Fuel Flow Caused
by Anti-Siphon Valves
preceding
Low fuel level in fuel tank 1 Fill tank with fuel
Plugged fuel tank pick-up screen Clean/replace fuel pick-up
screen
Hole/cut in pick-up tube of fuel Replace fuel pick-up tube
tank 1
Loose fuel line connection 1 Check/tighten all connections
Hole/cut in fuel line 1 Inspect/replace fuel hoses
Fuel line primer bulb check Replace fuel line primer bulb
valves not opening
Fuel hose/line internal diameter Use 8 mm (5/16 in.) fuel hose
too small
Restriction in fuel line thru-hull Clean/replace fitting
fitting
Restriction in fuel tank switching Clean/replace valve
valve
Restriction within primer bulb Rebuild/replace primer bulb
Pinched/collapsed fuel hose Inspect/replace fuel hoses
Dirty/plugged water separating Clean/replace water separating
fuel filter fuel filter
Fuel filter bowl loose 1 Tighten fuel filter bowl
Fuel filter gasket cut/worn 1 Replace gasket
Loose fuel pump screws 1 Torque screws to specification
Fuel pump gaskets worn or Rebuild/replace fuel pump
leaking 1
Fuel pump check valves/seals Rebuild/replace fuel pump
leaking
Leaky fuel pump diaphragm 1 Rebuild/replace fuel pump
Worn/broken fuel pump springs Rebuild/replace fuel pump
Leaky fuel pump seals Rebuild/replace fuel pump
Fuel vaporization Check for plugged fuel pump
water cooling circuit
1Air bubbles may also be visible as fuel passes through the clear fuel test hose installed
between the mechanical fuel pump outlet fitting and the VST.

Page 3B-10 90-883064R02 JULY 2006

 Troubleshooting and Diagnostics

EFI System Troubleshooting

The ECM is so designed that if a sensor fails the ECM will compensate so that the engine
does not go into an over-rich condition. Because of this, disconnecting a sensor for
troubleshooting purposes may have no noticeable effect.

Using the Digital Diagnostic Terminal (DDT)

IMPORTANT: Any sensor that is disconnected while the engine is running will be
recorded as a Fault in the ECM Fault History. Use the DDT to view and clear the fault
history when troubleshooting/repair is completed.

a c
d
b

e
f

4520

a - Digital Diagnostic Terminal

b - Software cartridge
c - DDT technical manual
d - DDT cable 3.05 m (10 ft.) extension
e - Adapter harness
f - Computer Diagnostic System

Digital Diagnostic Terminal 91-823686A2

Software cartridge 91-880118A04
DDT Technical Manual 90-881204A03
DDT cable 3.05 m (10 ft.) extension 84-825003A1
Adapter harness 84-822560A5
Computer Diagnostic System Order through SPX
NOTE: For additional information, pricing, or to order the Computer Diagnostic
System contact: SPX Corporation, 28635 Mound Rd., Warren MI 48092 or call:
USA 1-800-345-2233, Canada 800-345-2233, Europe 49 6182 959 149, or Australia
(03) 9544-6222.
The DDT and CDS has been developed specifically to help technicians diagnose and
repair Mercury Marine 2 and 4 cycle engines.
Attach the diagnostic cable to the ECM. The sensors and ECM data values including
status switches can all be monitored. The ECM program can help diagnose intermittent
engine problems. It will record the state of the engine sensors and switches for a period
of time and then can be played back to review the recorded information.
For the DDT, refer to the DDT Technical Manual for complete diagnostic procedures. For
the CDS, follow the computer on-screen diagnostics.

90-883064R02 JULY 2006 Page 3B-11

 Troubleshooting and Diagnostics

DDT Functions -- 4-Stroke EFI Models

02MY EFI xx HP 747cc
ECM #859613-X Any fault will turn on fault light. Refer to
CODE Fault Status to identify fault.
SPARK PLUG
CHAMPION RA8HC
GAP 0.040 (1 mm)
FIRING ORDER FAULT LIGHTS FAULT LIGHTS
SmartCraft Monitor 1-2-3
BATV 12.6 - 15.0
1 - Mercury Marine
IGNITION TIMING:
2 - Tool Setup IDLE ECM CONTROL IGNITION 1 5 SWITCHES
1800 - 2000 17° BTDC
6000 RPM 28° BTDC INJECTOR 2 6 MISCELLANEOUS
STATOR
0.2 - 0.3 ohm PUMP 3 7 RPM LIMIT
THIS ENGINE IS A CPS 300 - 500 ohm
IGN SEC 3 - 7 K ohm SENSORS
xx MY EFI xxx HP xxxcc 4 8 BREAK-- IN
FINJ 10.0 - 13.5 ohm
PRESS 1 to CONTINUE PWR RLY 81 - 99 ohm
IAC 24 - 30 ohm
MAT/ECT
10 K ohm @ 77° F/25° C
RPM LIMIT 6200
ENGINE RPM
PROP RPM 5500 - 6000
Select Function: Select Auto Test: BATTERY VOLTS
TYPICAL TPS RANGE
1 - AUTO SELF TEST PWR 1 VOLTS
1 -- STATIC TEST MAP PSI TPI 0.39 - 1.00 v IDLE
TRIGGER ERR 3.66 - 4.80 v WOT
2 - MANUAL TEST AVAILABLE PWR % MAP 3.5 - 15 PSI
IAC PWM % 24 - 103 kPa
SPARK ANG _TDC FUEL 42 - 44 PSI
ECT °F 290 - 303 kPa
TPS 1 VOLTS 1 FUSE - BUS +12 v
TPS % 2 FUSE - INJ/IAC/PMP
MAT °F 3 FUSE - MAIN RELAY
4 FUSE - IGN COIL
OVERTEMP/LOW OIL
PRESSURE LIMITS Fault Status List
ARE CONTROLLED BY
ENGINE GUARDIAN
Select Function: MAT INPUT HI or LO Manifold Air Temperatrure (engine) sensor input is high or low
1 - DATA MONITOR
2 - FAULT STATUS BATT VOLT HI or LOW Battery voltage is high or low
3 - SYSTEM INFO
4 - HISTORY ECT INPUT HI or LO Engine Coolant Temperature sensor input is high or low
5 - SPECIAL FUNCTIONS EST 1 thru 4 SHORT or OPEN Electronic spark trigger signal (1 thru 4) is short or open circuit
FREEZE FRAME BUFFERS FINJ 1 thru 4 SHORT or OPEN Fuel injector (1 thru 4) is short or open circuit
Select Function: Select Fault Hist: 0 thru 9
1 - FAULT HISTORY 1 -- FREEZE FRAME Note: Select Desired Buffer GUARDIAN Guardian system activated
2 - RUN HISTORY
2 -- FAULT SECONDS
3 - CLEAR FAULT HIST MAP INPUT HI or LO MAP sensor input high or low
4 - CLEAR RUN HIST
FREEZE FRAME BUFFERS MPRLY BACKFEED Main Power Relay is Receiving a Current Back feed

Selected Buffer: x - xxxxx MPRLY OUTPUT Main Power Relay Output

BARO PSI
FAULT SECONDS BATT VOLTS OVERSPEED Overspeed is activated
BATT VOLT HIGH BLOCK PSI
Select Function: BOAT SPEED COOL TMP OVRHT Engine overheat
BATT VOLT LOW
1 - OIL PUMP PRIME BLOCK PSI LOW AIR TMP °F
2 - CYLINDER MISFIRE COOL TMP °F TPS1 CKT HI or LO TPS #1 sensor input is high or low
COMP OVERHEAT
3 - OUTPUT LOAD TEST ETC MOTOR OPEN DEMAND %
RUN TIME HR. TPS1 NO ADAPT ECM is unable to adapt to the current position of the TPS
4 - RESET BREAK-IN OIL ETC MOTOR SHORT ENGINE RPM
RPM 0 -- 799
5 - CHANGE FUEL OFFSET FUEL PSI IN HI ENGINE STATE
RPM 800 -- 1499 TPS1 RANGE HI or LO TPS #1 is above or below the allowable range
6 - ENGINE LOCATION FUEL PSI IN LO FPC TOTAL
RPM 1500 -- 1999
7 - TRIM LIMIT GUARDIAN FREQ COUNTER
RPM 2000 -- 2999 WARNING HORN Warning horn fault
KNOCK SENS1 FUEL LEVEL %
RPM 3000 -- 3999
KNOCK SENS2 SHIFT
RPM 4000 -- 4499
Select Load Test: OIL PSI STR LAKE/SEA TMP °F
RPM 4500-- 4999
1 - IGNITION OIL REMOTE STR LOAD%
RPM 5000 -- 5999
2 - FUEL INJECTOR OIL RESERVE STR MPRLY REQ
RPM 6000 +
3 - DIRECT INJECTOR MAP INPUT HI MAP PSI
BREAK-IN LEFT
4 - OIL PUMP MAP INPUT LO OIL LEVEL %
RPM LIMIT Sec
5 - FUEL PUMP MAP IDLE CHECK PORT TAB POS
GRD LIMIT Sec
6 - HORN OIL PUMP AVAILABLE PWR %
CTS TMP Sec
7 - MISCELLANEOUS OVERSPEED RUN TIME
1 - IDLE AIR CONTROL PORT OVERHEAT STAR TAB POS
8 - TACHOMETER STAR OVERHEAT TPI %
9 - RELAYS WARNING HORN TRIM POSITION
1 - MAIN POWER RELAY H2O IN FUEL
2 - FUEL PUMP RELAY

90-883064R02 JULY 2006 Page 3B-13

 Troubleshooting and Diagnostics

Troubleshooting Without Digital Diagnostic Terminal

Troubleshooting without the DDT is limited to checking resistance on some of the sensors.
Typical failures usually do not involve the ECM. Connectors, set-up, and mechanical wear
are most likely at fault.
• Verify spark plug wires are securely installed (pushed on) on the coil tower.
• The engine may not run or may not run above idle with the wrong spark plugs installed.
• Swap ignition coils to see if the problem follows the coil or stays with the particular
cylinder.
NOTE: ECM’s are capable of performing a cylinder misfire test to isolate problem cylin-
ders. Once a suspect cylinder is located, an output load test on the ignition coil or fuel injec-
tor can be performed using the DDT.
• Any sensor or connection can be disconnected and reconnected while the engine is
operating without damaging the ECM. Disconnecting the crank position sensor will
stop the engine.
IMPORTANT: Any sensor that is disconnected while the engine is running will be
recorded as a Fault in the ECM Fault History. Use the DDT to view and clear the fault
history when troubleshooting/repair is completed.
• If all cylinders exhibit similar symptoms, the problem is with a sensor or harness input
to the ECM.
• If the problem is speed related or intermittent, it is probably connector or contact
related. Inspect the connectors for corrosion, loose wires or loose pins. Secure
connector seating; use dielectric compound.
• Inspect the harness for obvious damage: pinched wires, chafing.
• Secure grounds and all connections involving ring terminals. Coat with Liquid
Neoprene.

Tube Description Mercury Part Quicksilver Part

Ref. No. Number Number
25 Liquid Neoprene N/A 92-25711-3

• Check the fuel pump connections and fuel pump pressure.

Guardian Protection System

The Guardian Protection System monitors critical engine functions and will reduce engine
power in an attempt to keep the engine running within safe operating parameters.
IMPORTANT: The Guardian System cannot guarantee that powerhead damage will
not occur when adverse operating conditions are encountered. The Guardian
System is designed to (1) warn the boat operator that the engine is operating under
adverse conditions and (2) reduce power by limiting maximum RPM in an attempt
to avoid or reduce the possibility of engine damage. The boat operator is ultimately
responsible for proper engine operation.

90-883064R02 JULY 2006 Page 3B-15

Troubleshooting and Diagnostics

Warning Horn/Guardian System Operation

Sound Condition Description
One beep on key up Normal System test
Six beeps on key up, Failure detected with MAP, MAT 1, Engine should run well, however,
or during a running failure TPS, or Flash Check Sum (ECM) service will be required.
Three beeps every 4 minutes Failure detected with: Engine will start hard, run rough
• Battery voltage 1 and/or stall. Utilizing the neutral
• EST 1- Open detected at key fast idle feature may assist start-
up. Short detected with engine ing. Service is required.
running.
• Fuel injector - Detected while
cranking/running 1
• Coolant sensor 1
• IAC 2
Intermittent beeps Failure detected with: Engine may or may not start. If the
• Fuel pump - May start engine starts it easily stalls.
momentarily 2 Service is required.
• Main Power Relay - No start 2
• ECM reference voltage to
MAP/TPS - Starts but stalls
under load
Continuous Engine overheat Engine Guardian System is acti-
vated. Power limit will vary with
level of overheat. Stop engine and
check water intake for obstruction.
Advancing throttle above idle may
provide additional cooling.
Low oil pressure Guardian System is activated.
Engine power is limited to 10% of
maximum. Stop engine and check
oil level. Add oil if necessary.
Battery voltage Engine Guardian System is acti-
less than 10 v or more than 16 v vated. Engine power is limited to
75% of maximum.
Coolant sensor failure Engine Guardian System is acti-
vated. Engine power is limited to
50% of maximum. Engine over-
heat protection is compromised.
Engine speed limiter Exceeding 6200 RPM cuts spark/
injection on cylinder #2 to reduce
engine speed.
Exceeding 6350 RPM cuts spark/
injection on all cylinders to reduce
engine speed.
1 Horn beeps once on key up, plus failure code.
2 Sticky Fault requires key off to reset.

Page 3B-16 90-883064R02 JULY 2006

 Troubleshooting and Diagnostics

EFI System Troubleshooting Guide

IMPORTANT: In all instances, check wiring harness integrity, especially ground connections in
boat and on engine.
Condition Cause/Fault Warning Check
Mode
Engine cranks Lanyard stop switch is in the None Set lanyard stop switch to “RUN”.
but will not start “OFF” position
Weak battery or bad starter 3 beeps Check condition of battery/starter
motor. Battery voltage drops every 4 solenoid terminals and cables.
below 8 volts while cranking minutes for Charge/replace battery. Inspect condition
(ECM cuts out below 6 volts) low battery of starter motor.
(Fuel pump requires 8 volts). voltage.
Blown Fuse None Replace fuse. Inspect engine wiring
harness and electrical components.
Fuse #2 - Fuel Injectors/IAC/Fuel Pump
Fuse #3 - Main Power Relay/Accessory
Fuse #4 - Ignition Coils
Test Suppression Diode
Main Power Relay Intermittent Listen for relay to click when key switch is
beeps turned to “ON”.
81 - 99 ohms
Between pin #22 (yellow/purple) of port
ECM connector and (red/blue) wire of
fuse #3 (fuse removed).
- or -
Between pin #85 and pin #86 of relay.
Crank Position Sensor None 300 - 350 ohms
(CPS) Note: Between pin #5 (red) and pin #6 (white) of
No RPM starboard ECM connector.
reading at - or -
tachometer
Between pin #1 (red) and pin #2 (white) of
CPS connector.
Electric fuel pump Intermittent Listen for pump. Fuel pump should run 2
beeps seconds after key switch is turned to
“RUN” position.
32 - 41 ohms
Between pin #19 (black/blue) and pin #23
(red/blue).
- or -
Between pins of fuel pump connector.
Flywheel misaligned None Remove flywheel and inspect flywheel
key/key way.
Engine Coolant Temperature 3 beeps See ECT sensor resistance chart -
(ECT) sensor every 4 Section 3B - Electronic Fuel Injection.
minutes Advancing the remote control fast idle
feature or advancing the tiller handle
throttle grip halfway may assist starting.

90-883064R02 JULY 2006 Page 3B-17

Troubleshooting and Diagnostics

IMPORTANT: In all instances, check wiring harness integrity, especially ground connections in
boat and on engine.
Condition Cause/Fault Warning Check
Mode
Engine cranks, Remote control to engine None Clean and inspect male and female
starts and stalls wiring harness connection is connections.
poor
Air in fuel system/lines None Crank and start engine several times.
Manifold Absolute Pressure 6 beeps at See MAP sensor resistance chart -
(MAP) sensor key up or Section 3B - Electronic Fuel Injection.
failure
Throttle Position Sensor 6 beeps at Typical TPI range with DDT:
(TPS) key up or Idle 0.39 - 1.0 volts,
failure WOT 3.66 - 4.80 volts.
Idle Air Control (IAC) 3 beeps 24 - 30 ohms
every 4 Between pin #20 (white/orange) and pin
minutes #23 (red/blue) of starboard ECM
connector.
- or -
Between pin A and pin B of IAC.
ECM reference voltage to Intermittent 5 volts
MAP/TPS beeps Between purple/yellow pin of the MAP
sensor wiring harness connector and the
engine ground, key switch to “RUN”.
Fuel pressure at VST fitting None See fuel pressure test - Section 3B -
Electronic Fuel Injection.
Flywheel misaligned None Remove flywheel and inspect flywheel key
and key way.
Engine idles fast Engine Coolant Temperature 3 beeps See ECT sensor resistance chart -
after warm-up (ECT) sensor every 4 Section 3B - Electronic Fuel Injection.
(900-1100 RPM) minutes
Poor off idle or Fuel injector 3 beeps 10.0 - 13.5 ohms
WOT running every 4 Between fuel injector pin #1 and pin #2.
quality minutes
- or -
Between (removed) fuse #2 (red/blue)
wire and port ECM connector:
Pin #17 (pink/brown) Fuel injector #1
Pin #2 (pink/red) Fuel injector #2
Pin #1 (pink/orange) Fuel injector #3
Ignition coil (EST) 3 3 beeps See ignition coil resistance chart -
every 4 Section 2A - Ignition.
minutes
Fuel pressure at VST fitting None See fuel pressure test - Section 3B -
Electronic Fuel Injection.
Fuel filter plugged None Replace fuel filter.
Improper spark plugs None Use recommended suppressor (resistor)
spark plugs.
Loose grounds None Check all ground connections.
Flywheel timing tooth pattern None Check tooth pattern for partially missing
or damaged teeth.
Fouled spark plugs None Replace spark plugs.
3 The ECM will only monitor the EST connection to the ignition coil, use resistance tests and/or spark gap
test to confirm an ignition coil failure.

Page 3B-18 90-883064R02 JULY 2006

 Troubleshooting and Diagnostics

IMPORTANT: In all instances,check wiring harness integrity, especially ground connections in

boat and on engine.
Condition Cause/Fault Warning Check
Mode
Poor idle quality Crank Position Sensor None 300 - 350 ohms
(CPS) Between pin #5 (red) and pin #6 (white)
of starboard ECM connector.
- or -
Between pin #1 (red) and pin #2 (white) of
CPS connector.
Manifold Absolute Pressure 6 beeps at See MAP sensor resistance chart -
(MAP) sensor key up or Section 3B - Electronic Fuel Injection.
failure
Throttle Position Sensor 6 beeps at Typical TPI range with DDT:
(TPS) key up or Idle 0.39 - 1.0 volts,
failure WOT 3.66 - 4.80 volts.
Engine Coolant Temperature 3 beeps See ECT sensor resistance chart -
(ECT) sensor every 4 Section 3B - Electronic Fuel Injection.
minutes

Manifold Air Temperature 6 beeps at See MAT sensor resistance chart -

(MAT) sensor key up or Section 3B - Electronic Fuel Injection.
failure
Fuel injector 3 beeps 10.0 - 13.5 ohms
every 4 Between fuel injector pin #1 and pin #2.
minutes
- or -
Between (removed) fuse #2 (red/blue)
wire and port ECM connector:
Pin #17 (pink/brown) Fuel Injector #1
Pin #2 (pink/red) Fuel Injector #2
Pin #1 (pink/orange) Fuel Injector #3
Ignition coil (EST) 3 3 beeps See ignition coil resistance chart -
every 4 Section 2A - Ignition.
minutes
Idle Air Control (IAC) 3 beeps 20 - 24 ohms
every 4 Between pin #20 (white/orange) and pin
minutes #23 (red/blue) of starboard ECM
connector.
- or -
Between pin A and pin B of IAC.
Fuel pressure at VST fitting None See fuel pressure test - Section 3B -
Electronic Fuel Injection.
Loose grounds None Check all ground connections.
Fouled spark plugs None Replace spark plugs.
3 The ECM will only monitor the EST connection to the ignition coil, use resistance tests and/or spark gap
test to confirm an ignition coil failure.

90-883064R02 JULY 2006 Page 3B-19

Troubleshooting and Diagnostics

IMPORTANT: In all instances, check wiring harness integrity, especially ground connections in
boat and on engine.
Condition Cause/Fault Warning Check
Mode
Engine runs rich Fuel pressure regulator None 290 - 303 kPa (42 - 44 PSI) at VST fitting
- Section 3B - Electronic Fuel Injection.
Engine Coolant Temperature 3 beeps See ECT sensor resistance chart -
(ECT) sensor every 4 Section 3B - Electronic Fuel Injection.
minutes
Thermostat stuck open None Remove and inspect thermostat.
Section 4A - Cylinder Head.
Speed reduction Low oil pressure or Guardian Check engine oil level and add oil as
engine RPM grounded oil pressure switch continuous needed.
limited to 2000 lead horn above Remove oil pressure switch and install oil
10% power pressure gauge, (warm engine) oil pres-
setting sure should be:
Above 20.0 kPa (2.9 PSI) at idle,
207 - 278 kPa (30 - 40 PSI) at 3000 RPM.
See Section 4B - Oil Pressure Switch
test.
Check for short between pin #7 (blue) of
starboard ECM connector and open con-
nector of oil pressure switch.
Speed reduction Engine overheat Guardian Engine Guardian System is activated.
engine RPM continuous Power limit will vary with level of overheat.
limited Stop engine and check water intake for
obstruction.
Advancing throttle above idle may provide
additional cooling.
Battery voltage Guardian Engine Guardian System is activated.
less than 10 v or more than continuous Engine power is limited to 75% of
16 v horn above maximum.
75% power
setting
Engine Coolant Temperature Guardian Engine Guardian System is activated.
(ECT) sensor failure continuous Engine power is limited to 50% of
horn above maximum. Engine overheat protection is
50% power compromised.
setting

Page 3B-20 90-883064R02 JULY 2006

 Troubleshooting and Diagnostics

Component Resistance Tests

NOTE: Refer to Section 1 - General Information (powerhead reference views) for location
of sensors.
NOTE: If using a digital meter, turn the selector switch to Ω. Allow the meter to auto-range.

DMT 2000 Digital Multimeter Tachometer 91-892647A01

Engine Coolant Temperature (ECT) Sensor and Manifold Air Temperature

(MAT) Sensor
1. Place the ECT sensor in a container filled with water.
2. Place a thermometer in the water and slowly heat the water.
3. Measure the resistance when the specified temperature is reached. If the reading is
out of specification, replace the sensor.

a - Engine Coolant Temperature (ECT) sensor

270
255
240
Test Water Temperature ( F)

° 225
210
195
Temperature Sensor
180
165
150
135
120
105
90
75
60
45
30
15
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32

Resistance (kΩ)

90-883064R02 JULY 2006 Page 3B-21

Troubleshooting and Diagnostics

Fuel Injector

b a

Meter Scale Reading

Meter Test Leads
(Analog) (Ω)
Red Black
Rx1 10 - 13.5
13 5
Pin A Pin B

Main Power Relay

85 86

Meter Scale Reading

Meter Test Leads
(Analog) (Ω)
Red Black
Rx1 81 - 91
Pin 85 Pin 86

Page 3B-22 90-883064R02 JULY 2006

 Troubleshooting and Diagnostics

Manifold Absolute Pressure (MAP) Sensor

b

c a

a - Black/Orange
b - Yellow
c - Purple/Yellow
Meter Scale Reading
Meter Test Leads
(Analog) (Ω)
Red Black
95 - 105 k
Pin A Pin B
R x 1k 3 9 - 4.3
3.9 43k
Pin A Pin C
95 - 105 k
Pin B Pin C

Crank Position Sensor

Meter Scale Reading

Meter Test Leads
(Analog) (Ω)
Red Black
Rx1 300 - 350
Red White

90-883064R02 JULY 2006 Page 3B-23

 Service Procedures

Electronic Fuel Injection

Section 3C - Service Procedures
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-2 Throttle Position Sensor (TPS) . . . . . . . . . . . . 3C-34
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-34
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . .
Vapor Separator Components
3C-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3C-34
3C-35
3
S/N 1B036613 And Below . . . . . . . . . . . . . . . 3C-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-35 C
Vapor Separator Components Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-35
S/N 1B036614 And Above . . . . . . . . . . . . . . . 3C-12 Crank Position Sensor Removal/Installation 3C-36
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-14 Engine Coolant Temperature (ECT) Sensor
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-16 Removal/Installation . . . . . . . . . . . . . . . . . . . . 3C-37
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 3C-17 Low Pressure Fuel Line/Fuel Pump . . . . . . . . 3C-38
Intake Manifold Assembly . . . . . . . . . . . . . . . . 3C-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-38
Releasing Fuel Pressure in the High Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3C-38
Pressure Fuel Line . . . . . . . . . . . . . . . . . . . 3C-18 Cleaning/Inspection/Repair . . . . . . . . . . . . 3C-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-19 Check Valve Inspection/Replacement . . . 3C-40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-22 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-41
Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-26 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-26 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3C-45
Idle Air Control (IAC) . . . . . . . . . . . . . . . . . . . . . 3C-27 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-27 Vapor Separator (VST) S/N 1B036613
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-27 And Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-46
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-28 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-28 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3C-47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-29 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-49
Manifold Absolute Pressure (MAP) Sensor . 3C-30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-30 Vapor Separator (VST) S/N 1B036614
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-30 And Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-52
Fuel Distribution Manifold . . . . . . . . . . . . . . . . 3C-31 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-31 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3C-52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-32 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-55
Manifold Air Temperature (MAT) Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-59
Removal/Installation . . . . . . . . . . . . . . . . . . . . 3C-33 Pressure Regulator Removal/Installation . . . 3C-60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-33 1B036613 And Below . . . . . . . . . . . . . . . . . 3C-60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-33 High Pressure Fuel Line Removal/Installation 3C-61

90-883064R02 JULY 2006 Page 3C-1

Service Procedures

Special Tools
1. DMT 2000 Digital Multimeter Tachometer P/N 91-892647A01

2. Digital Diagnostic Terminal P/N 91-823686A2

3. DDT Cartridge P/N 91-880118A04

4. Computer Diagnostic System

NOTE: For additional information, pricing, or to order the Computer Diagnostic
System contact: SPX Corporation, 28635 Mound Rd., Warren MI 48092 or call:
USA 1-800-345-2233, Canada 800-345-2233, Europe 49 6182 959 149, Australia
(03) 9544-6222.

4520

5. Fuel Injector Cap Tool P/N 91-883877A1

58816

Page 3C-2 90-883064R02 JULY 2006

 Service Procedures

6. Clamp Tool Kit P/N 91-803146A04

57316

a - Clamp Tool P/N 91-803146T

7. Fuel Pressure Gauge

a
b

a - 91-881833A03
b - 91-881834A1

90-883064R02 JULY 2006 Page 3C-3

Service Procedures

Specifications
Fuel Pump Type Mechanical Water Cooled
(Plunger/Diaphragm)
Fuel
Fuel Pump:
System
Pressure 20.7 - 41 kPa (3 - 6 PSI)
Fuel Tank Capacity Accessory
Fuel Injector System Batch
Idle RPM (Out of Gear) 775 ± 25 RPM
Fuel Injection
Idle RPM (In Forward Gear) 775 ± 25 RPM
Wide Open Throttle RPM (WOT)
Range 5500 - 6000
Fuel Pump Pressure - Electric 290 - 303 kPa (42 - 44 PSI)

Page 3C-4 90-883064R02 JULY 2006

 Service Procedures

Notes:

90-883064R02 JULY 2006 Page 3C-5

Service Procedures

Intake Manifold

66

66

Page 3C-6 90-883064R02 JULY 2006

 Service Procedures

Intake Manifold
Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
1 1 Intake manifold
2 3 Gasket
3 1 Screw 3.5 31
4 1 Bracket
5 1 Nut 8.5 75
6 1 Idle Air Control (IAC)
7 1 Fuel distribution manifold
8 3 Injector
9 2 Screw 3.5 31
10 3 Screw 3.5 31
11 3 Clip
12 1 Hose
13 1 Throttle body
14 1 Gasket
15 2 Screw 3.5 31
16 1 Throttle Position Sensor (TPS)
17 2 Screw 2 18
18 1 Manifold Absolute Pressure (MAP) sensor
19 1 Manifold Air Temperature (MAT) sensor 1.4 12.5
20 1 O-ring
21 1 Sound attenuator
22 4 Screw (M6 x 25) 8.5 75
23 1 Breather hose
24 1 Restrictor (30)
25 1 Screw (M6 x 30) 8.5 75
26 3 Cable tie
27 1 Screw (10-16 x .625) Drive Tight
28 1 Retainer

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

66 Loctite 242 92-809821 92-809821

90-883064R02 JULY 2006 Page 3C-7

Service Procedures

Vapor Separator Components S/N 1B036613 And Below

66 11

12 9

13 2
3 2
4 1
9 14 22
15
6 11
11
8
7
17 21
20 16
5 24
9 10 23
19

9
26
12
66 12

25 18

33

27
29
41
40 28
43 44
33 66
46
34
9
32 45
38
39

30
35
9
37
36 31

42

Page 3C-8 90-883064R02 JULY 2006

 Service Procedures

Vapor Separator Components S/N 1B036613 And Below

Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
1 1 Cover kit
2 2 Fitting
3 1 Electrical pass-thru kit 5.6 50
4 1 O-ring
5 1 Retainer
6 1 Fitting 5.6 50
7 1 Fitting 5.6 50
8 1 Diagnostic valve 5.6 50
9 1 Cap
10 1 Drain tube
11 5 Screw 4.3 38
12 6 Screw 2.5 22
13 1 Regulator
14 1 O-ring
15 1 O-ring
16 1 Seal kit 3.7 33
17 1 Gasket
18 1 Float kit
19 1 Float shaft
20 1 Inlet needle kit
21 1 Vent hose
22 1 Cable tie
23 1 Fuel baffle
24 1 Harness
25 1 Pump kit
26 1 Sleeve
27 1 Grommet
28 1 Fuel bowl kit
29 1 Gasket
30 1 Drain screw 8.5 75
31 1 Fitting Press to shoulder
32 1 Fuel cooler body kit
33 4 Clamp
34 2 Fitting 5.6 50
35 5 Plug
36 2 Elbow fitting Install 5 to 7 turns
37 1 Elbow fitting 6.2 55
38 1 Screw 16.3 12
39 1 Gasket
40 1 Hose (1-5/8)
41 1 Hose (4-1/2)
42 1 Drain hose

90-883064R02 JULY 2006 Page 3C-9

Service Procedures

Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
43 3 Bushing
44 3 Grommet
45 3 Screw (M6 x 25) 5.1 45
46 3 Washer

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
Loctite 567 PST Pipe
9 92-809822 92-809822
Sealant

66 Loctite 242 92-809821 92-809821

Page 3C-10 90-883064R02 JULY 2006

 Service Procedures

Vapor Separator Components S/N 1B036613 And Below

66 11

12 9

13 2
3 2
4 1
9 14 22
15
6 11
11
8
7
17 21
20 16
5 24
9 10 23
19

9
26
12
66 12

25 18

33

27
29
41
40 28
43 44
33 66
46
34
9
32 45
38
39

30
35
9
37
36 31

42

90-883064R02 JULY 2006 Page 3C-11

Service Procedures

Vapor Separator Components S/N 1B036614 And Above

2
16

17
3

1
18

8
9
4
10 19
7
5
20
11
21
12
6
22
13
23

14
24
15 4

25
30
26
27
29

28

9009

Page 3C-12 90-883064R02 JULY 2006

 Service Procedures

Vapor Separator Components S/N 1B036614 And Above

Torque
Ref
Ref.
No. QTY. Description Nm lb. in. lb. ft.
1 1 VST cover assembly
2 1 Electrical connector
3 5 Screw (M4 x 16) 2.5 22
4 4 Hose clamp
5 1 Pressure regulator kit
6 1 Screw (M5 x 18) 2.5 22
7 1 Cap
8 1 O-ring
9 1 Fuel seat
10 1 Fuel inlet needle
11 1 Baffle plate
12 3 Screw (M4 x 8) 2.5 22
13 1 Float pin
14 2 Screw (M4 x 8) 2.5 22
15 1 Float
16 1 Insulator
17 1 Cover
18 1 High pressure fuel pump
19 1 Isolator
20 1 Insulator
21 1 Fuel strainer
22 1 O-ring seal
23 3 Bushing
24 3 Grommet
25 1 Fuel cooler
26 1 Screw (M6 x 25) 3.5 32
27 1 Washer
28 1 Hose
29 1 Drain screw
30 1 VST body assembly

90-883064R02 JULY 2006 Page 3C-13

Service Procedures

Fuel Pump
21
20 22

23 19
13 A
B
24 13
18
15 10
25
11
13
14
13
8

13

17
13 9
13
1 2
16 13
12

3 3

4
3
5
3 3
66
1
3
6
7

Page 3C-14 90-883064R02 JULY 2006

 Service Procedures

Fuel Pump
Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
1 1 Fuel pump
2 4 Screw 4 35
3 1 Diaphragm/O-ring kit
4 1 Spring
5 4 Nut
6 1 Spring
7 1 Cap
8 1 Cowl deflector
9 2 Screw (M6 x 30) 8.5 75
10 1 Tubing (29 in.)
11 1 Tubing (16 in.)
12 1 Tubing (6 in.)
13 AR Cable tie
14 1 Tubing (8 in.)
15 1 Fuel filter
16 1 Tubing (38 in.)
17 1 Fuel connector
18 1 Bushing
19 1 Grommet
20 1 Washer
21 1 Nut (M6) 5.1 45
22 1 Bracket
23 2 Screw (M6 x 13) 8.5 75
24 1 Conduit (13 in.)
25 1 Conduit (26 in.)
A = To Vapor Separator Cover
B = To VST Cooler
C = To Tell Tale

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

66 Loctite 242 92-809821 92-809821

90-883064R02 JULY 2006 Page 3C-15

Service Procedures

Fuel Lines
1

Fuel Lines
Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
1 1 Conduit (22 in.)
2 1 Fuel line
3 1 Fuel filter
4 1 Protective sleeve
5 1 Fuel line

Page 3C-16 90-883064R02 JULY 2006

 Service Procedures

Torque Sequence

Intake Manifold Flange

Tighten screws in the sequence shown to the specified torque.

3
4

1
2

Description Nm lb. in. lb. ft.

Intake manifold screw 8 70

90-883064R02 JULY 2006 Page 3C-17

Service Procedures

Intake Manifold Assembly

WARNING
Always release the fuel pressure in the high pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel
may spray out.

Releasing Fuel Pressure in the High Pressure Fuel Line

1. Install the fuel pressure gauge onto the pressure check valve.
2. Place the drain hose into a container.
3. Push the relief button, and release the pressure.

a - Fuel pressure gauge

b - Pressure relief button
c - Drain hose
Fuel Pressure Gauge 91-88183A03

Page 3C-18 90-883064R02 JULY 2006

 Service Procedures

Removal
1. Push in the fuel injector harness connector retaining clip, and unplug the harness from
each fuel injector. It is not necessary to remove the retaining clip from the connector.
2. Unplug the Idle Air Control (IAC) connector.
3. After relieving pressure disconnect the high pressure fuel line from the fuel
distribution manifold by depressing the locking tab, and pulling back on the fuel line.
4. Remove the flywheel cover.

f
g

e
b

d
c
58983

a - Fuel injector (4)

b - Harness connector retaining clip
c - Idle Air Control (IAC) connector
d - Throttle air bypass hose
e - High pressure fuel line
f - Locking tab
g - Flywheel cover

90-883064R02 JULY 2006 Page 3C-19

Service Procedures

5. Remove the intake assembly mounting screws, and remove the intake assembly.

c 58981

a - Intake assembly mounting screw (4) (M6 x 25)

b - Intake assembly mounting screw (1) (M6 x 30)
c - Intake assembly mounting screw (2) (M6 x 40)

6. Disconnect the throttle link rod from the throttle body ball socket.

a - Throttle link rod

b - Throttle body ball socket

Page 3C-20 90-883064R02 JULY 2006

 Service Procedures

7. Disconnect the ECM harness connectors.

8. Remove the ECM mounting screws, and washers. Remove the ECM from the mount-
ing plate.
b
e

a c

b
b d 58811

a - ECM harness connectors

b - ECM mounting screw (3) (M6 x 25)
c - ECM
d - J-clip
e - Washers (3)

9. Disconnect the following sensors: MAP, MAT, and TPS.

10. Cut the cable tie, and remove the crankcase breather hose from the sound attenuator.
Remove the intake assembly from the engine.

f
b
e
d
a

g 58978

a - MAP sensor
b - MAP sensor retaining clip
c - Screw (10-16 x 0.625)
d - MAT sensor connector
e - TPS connector
f - Crankcase breather hose
g - Sound attenuator

90-883064R02 JULY 2006 Page 3C-21

Service Procedures

Installation
1. Install the intake manifold assembly to the engine. Make sure the O-rings are in place.
Tighten the screws in sequence shown to the specified torque.

6
66

b 3
4

1
2
66 a

58981

c
a - Intake assembly mounting screw (4) (M6 x 25)
b - Intake assembly mounting screw (M6 x 30)
c - Intake assembly mounting screw (2) (M6 x 40)
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

66 Loctite 242 92-809821 92-809821

Description Nm lb. in. lb. ft.

Intake assembly mounting screw 8.5 75

2. Connect the throttle link rod to the throttle body ball socket.
IMPORTANT: Check for the proper throttle link rod adjustment as outlined in
Section 7A.

b
a

a - Throttle link rod

b - Throttle body ball socket

Page 3C-22 90-883064R02 JULY 2006

 Service Procedures

3. Connect the following sensors: MAP, MAT, and TPS.

4. Install the MAP sensor retaining clip, and then tighten the screw.
5. Install the crankcase breather hose into the sound attenuator. Secure with a cable tie.

b f

e
a d

g 58978

a - MAP sensor
b - MAP sensor retaining clip
c - Screw (10-16 x 0.625)
d - MAT sensor connector
e - TPS connector
f - Crankcase breather hose
g - Sound attenuator

90-883064R02 JULY 2006 Page 3C-23

Service Procedures

6. Connect the fuel line to the fuel distribution manifold. Push on until locked into place.
7. Route the injector harness as shown, and plug in the fuel injector, and IAC connectors.
8. Install the flywheel cover. Tighten screws to the specified torque.

f
g

d
c 58983

a - Fuel injector (3)

b - Fuel injector connector (3)
c - IAC connector
d - Throttle air bypass hose
e - Fuel line
f - Locking tab
g - Flywheel cover
Description Nm lb. in. lb. ft.
Flywheel cover screw 8.5 75

Page 3C-24 90-883064R02 JULY 2006

 Service Procedures

9. Install the ECM to the mounting plate. Tighten the mounting screws to the specified
torque.
10. Plug in the ECM harness connectors.
b
e

a c

b
b d 58811

a - ECM harness connectors

b - ECM mounting screw (3) (M6 x 25)
c - ECM
d - J-clip
e - Washers (3)
Description Nm lb. in. lb. ft.
ECM mounting screw 5.1 45

90-883064R02 JULY 2006 Page 3C-25

Service Procedures

Throttle Body
Removal
1. Remove the intake manifold assembly. Refer to Intake Manifold Assembly Removal.
2. Remove the throttle body mounting screws, and remove the throttle body assembly
from the intake assembly.
Installation
1. Lubricate O-ring, and install the throttle body to the intake assembly. Tighten screws to the
specified torque.
2. Install the intake assembly. Refer to Intake Assembly Installation.

d b
a

a - Throttle body mounting screws (2) 25 mm long

b - Throttle body assembly
c - Seal
d - Intake assembly
Description Nm lb. in. lb. ft.
Throttle body mounting screw 3.5 31

Page 3C-26 90-883064R02 JULY 2006

 Service Procedures

Idle Air Control (IAC)

Removal
1. Disconnect the IAC harness connector.
2. Remove the IAC mounting screw.
3. Disconnect the throttle air bypass hose, and remove the IAC valve.
Installation
1. Install the IAC, and secure with a mounting screw.
2. Connect the IAC harness connector, and the bypass hose.

c
b

d
a
a - IAC mounting screw
b - IAC harness connector
c - Throttle air bypass hose
d - IAC valve
Description Nm lb. in. lb. ft.
IAC mounting screw 3.5 31

90-883064R02 JULY 2006 Page 3C-27

Service Procedures

Fuel Injectors
WARNING
Always release the fuel pressure in the high pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel
may spray out.
Removal
1. Remove the fuel injector cap retaining clips, and screws.
2. Push in on the harness connector retaining clip, and unplug the harness from each fuel
injector.
3. Use the fuel injector cap tool to pry injector cap from the injector.
4. Remove the fuel injectors from the intake manifold.

b
d

a - Fuel injector (3)

b - Fuel injector cap (3)
c - Fuel injector cap retaining clip (3)
d - Screw (3)
e - Harness connector retaining clip (3)
f - Fuel injector cap tool
Fuel Injector Cap Tool 91-883877A1

Page 3C-28 90-883064R02 JULY 2006

 Service Procedures

Installation
1. Install the fuel injector cap by pushing it on the fuel injector until it bottoms out.
2. Lubricate the O-rings, and install the fuel injectors into the intake manifold.
3. Install the fuel injector cap retaining screws, and tighten to the specified torque. Install
the fuel injector cap retaining clips so that the locking teeth line up with the locking rib
on the fuel injector as shown.
4. Connect the harness connectors to each fuel injector. Push the connector on until the
retaining clip locks in place.

e
g h
f

58823

b
d

91-883877A1

a - Fuel injector (3)

b - Fuel injector cap (3)
c - Fuel injector cap retaining clip (3)
d - Fuel injector cap retaining screw (3)
e - Fuel injector harness retaining clip (3)
f - Fuel injector harness connector (3)
g - Locking teeth
h - Locking rib
Tube Ref. Quicksilver Part
Description Mercury Part Number
No. Number

110 4-Stroke 10W-30 Outboard Oil 92-802833A1 92-802833Q1

Fuel Injector Cap Tool 91-883877A1

Description Nm lb. in. lb. ft.

Fuel injector cap retaining screw 3.5 31

90-883064R02 JULY 2006 Page 3C-29

Service Procedures

Manifold Absolute Pressure (MAP) Sensor

Removal
1. Remove the intake assembly. Refer to Intake Assembly Removal.
2. Remove the MAP sensor retaining screw, and bracket. Remove the MAP from the intake
by pulling and twisting simultaneously.
Installation
1. Lubricate the seal, and push the MAP into the intake assembly.
2. Install the retaining clip, and screw. Tighten the screw securely.
3. Install the intake assembly. Refer to Intake Assembly Installation.

58978

a - MAP sensor
b - Retaining clip
c - Screw
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

Page 3C-30 90-883064R02 JULY 2006

 Service Procedures

Fuel Distribution Manifold

WARNING
Always release the fuel pressure in the high pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel
may spray out.
Removal
1. Remove the fuel injector cap retaining screws.
2. Remove the fuel injector cap retaining clips.
3. Use the fuel injector cap tool to pry the fuel injector cap off of each fuel injector.
4. Remove the fuel distribution manifold mounting screws.
5. After relieving the fuel pressure, disconnect the high pressure fuel line by depressing
the locking tab, and pulling back. Remove the fuel distribution manifold.

e
f

c
d

91-883877A1

58983

a - Fuel injector cap retaining screw (3)

b - Fuel injector cap (3)
c - Fuel injector cap retaining clip (3)
d - Fuel distribution manifold mounting screw (2)
e - Fuel distribution manifold
f - High pressure fuel line locking tab
Fuel Injector Cap Tool 91-883877A1

90-883064R02 JULY 2006 Page 3C-31

Service Procedures

Installation
1. Install the fuel distribution manifold, and tighten the mounting screws to the specified
torque.
2. Push the fuel injector cap onto the fuel injector until the cap bottoms out on the injector.
3. Install the fuel injector cap retaining screws, and tighten securely. Install the fuel injec-
tor cap retaining clips so that the locking teeth line up with the locking rib on the fuel
injector as shown.
4. Connect the high pressure fuel line. Push on until the locking tab snaps in place.

e
f

c
d

58983

a - Fuel injector cap retaining screw (3)

b - Fuel injector cap (3)
c - Fuel injector cap retaining clip (3)
d - Fuel distribution manifold mounting screw (2)
e - Fuel distribution manifold
f - High pressure fuel line locking tab
Description Nm lb. in. lb. ft.
Fuel distribution manifold mounting screw 3.5 31

Page 3C-32 90-883064R02 JULY 2006

 Service Procedures

Manifold Air Temperature (MAT) Sensor

Removal/Installation
Removal
1. Remove the intake manifold assembly. Refer to Intake Manifold Assembly Removal.
2. Disconnect the MAT sensor connector.
3. Unscrew the MAT sensor from the intake manifold assembly. Inspect the O-ring, and
replace if necessary.
Installation
CAUTION
Overtightening the Manifold Air Temperature (MAT) sensor can lead to failing the
plastic threads. Be sure to tighten to the specified torque.
1. Lubricate the O-ring, and screw in the air temperature sensor. Tighten to the specified
torque.
2. Connect the MAT sensor connector.
3. Install the intake manifold assembly. Refer to Intake Manifold Assembly
Installation.

b
c

58978

a - MAT sensor
b - MAT sensor connector
c - O-ring
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

Description Nm lb. in. lb. ft.

Air temperature sensor 1.4 12.5

90-883064R02 JULY 2006 Page 3C-33

Service Procedures

Throttle Position Sensor (TPS)

Removal
1. Remove the intake manifold assembly. Refer to Intake Manifold Assembly Removal.
2. Disconnect the TPS connector.
3. Remove the mounting screws, and remove the throttle position sensor.
Installation
1. Install the TPS. Tighten screws to the specified torque.
2. Connect the TPS connector.
3. Install the intake manifold assembly. Refer to Intake Manifold Assembly Installation.
c

b
a

58978

a - TPS
b - TPS connector
c - TPS mounting screws (2) 15 mm long
Description Nm lb. in. lb. ft.
Throttle position sensor mounting screw 2 18

Page 3C-34 90-883064R02 JULY 2006

 Service Procedures

ECM
Removal
1. Remove the ECM harness connectors.
2. Remove the ECM mounting screws, and washers. Remove the ECM from the mount-
ing plate.
Installation
1. Install the ECM onto the mounting bracket. Position the j-clip as shown. Install the
screws, and washers. Tighten screws to the specified torque.
2. Connect the ECM harness connectors.
b
e

a c

b
b d 58811

a - ECM harness connectors

b - ECM mounting screw (3) (M6 x 25)
c - ECM
d - J-clip
e - Washers (3)
Description Nm lb. in. lb. ft.
ECM mounting screw 5.1 45

90-883064R02 JULY 2006 Page 3C-35

Service Procedures

Crank Position Sensor Removal/Installation

1. Disconnect the sensor from the wiring harness.
2. Remove the sensor mounting screws.
3. Reverse the steps for installation. Tighten screws to the specified torque.

58228

a - Crank position sensor

b - Harness connector
c - Screw (2) (M5 x 16)
Description Nm lb. in. lb. ft.
Crank position sensor mounting screw 5.1 45

Page 3C-36 90-883064R02 JULY 2006

 Service Procedures

Engine Coolant Temperature (ECT) Sensor

Removal/Installation
1. Disconnect the sensor from the wiring harness.
2. Remove the sensor from the exhaust cover.
3. Reverse the steps for installation. Tighten to the specified torque.

CAUTION
Overtightening the coolant temperature sensor can lead to failing the plastic
threads. Be sure to tighten to the specified torque.

b c

58225

a - Harness connector
b - Temperature sensor
c - Exhaust cover
Description Nm lb. in. lb. ft.
Temperature sensor mounting 1.7 15

90-883064R02 JULY 2006 Page 3C-37

Service Procedures

Low Pressure Fuel Line/Fuel Pump

Removal
1. Cut the cable ties, and remove the fuel pump inlet/outlet hoses, and the fuel cooler
water inlet/outlet hoses.
2. Remove the fuel pump mounting bolts, and cowl deflector.
3. Separate the fuel pump from the cylinder head cover.

c a

g f

d 58974

a - Inlet fuel hose from filter

b - Outlet fuel hose to VST
c - Fuel cooler water inlet hose from VST fuel cooler
d - Fuel cooler water outlet hose to tell-tale outlet
e - Mounting screw (2) (M6 x 30)
f - Cowl deflector
g - Fuel pump

Disassembly
IMPORTANT: Before separating the fuel pump components mark each component
with an indelible marker. This will ensure the components are oriented correctly
during reassembly.

Page 3C-38 90-883064R02 JULY 2006

 Service Procedures

1. Remove the screws to separate the pump cover, cover seal, diaphragm, and valve
body from the pump base.

a
h
b
c
d
e

f
g

28378

a - Screws (4) e - Valve body

b - Pump cover f - Pump base
c - Cover seal g - Nuts (4)
d - Diaphragm h - Indelible marker

2. Rotate the plunger to line up the slots.

a b

53615

a - Slots offset
b - Slots aligned

3. Compress the pump assembly to free spring load on pin.

4. Tilt the assembly to allow the pin to slide out.

53617

a - Pin

90-883064R02 JULY 2006 Page 3C-39

Service Procedures

Cleaning/Inspection/Repair
1. Inspect the springs for damage, replace if necessary.

2. Inspect the cover seal, and diaphragm, replace if damaged.

b a

a - Cover seal
b - Diaphragm

Check Valve Inspection/Replacement

1. Inspect the check valves for damage, replace if necessary.

REMOVAL
1. If replacement is needed remove old check valves by grabbing the seal, and pulling.

a
58831

a - Check valve/seal assembly (2)

Page 3C-40 90-883064R02 JULY 2006

 Service Procedures

INSTALLATION
1. Fabricate an installation tool to the dimensions specified.
2. Lubricate the end of the seal, and push the assembly into the valve body.
NOTE: Drill into the handle using a 2 mm (5/64 in.) drill bit. Insert the peg into the drilled
hole until 8 mm (0.312 in.) remains exposed.

c e

d f

b 58832

a
58831

a - Check valve/seal assembly (2)

b - Installation tool
c - Valve body
d - 2 mm (5/64 in.)
e - 7.7 - 8.2 mm (0.312 in. - 0.010 in.)
f - 9.5 mm (0.735 in.)
Assembly
1. Assemble the springs, diaphragm, and plunger onto the pump base.

a - Diaphragm
b - Diaphragm spring
c - Pump body
d - Spring
e - Plunger

90-883064R02 JULY 2006 Page 3C-41

Service Procedures

2. Line up slots, and compress the assembly.

3. Insert the pin into the hole.

c
b

a - Pump body c - Pin

b - Slots

4. Rotate the plunger 90° to offset the slots.

a b

53615
a - Slots aligned b - Slots offset

5. Assemble valve body, diaphragm, seal, and cover to the pump base. Ensure to line up
indelible marker that was made before disassembly. Apply Loctite 242 to screws, and
secure with nuts.
NOTE: Seal installs in one direction only.

a
h

b
c
d
e

f
g
66 28378

a - Screws (4) (M5 x 40) e - Valve body

b - Pump cover f - Pump base
c - Cover seal g - Nuts (4)
d - Diaphragm h - I.D. marks
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

66 Loctite 242 92-809821 92-809821

Description Nm lb. in. lb. ft.

Fuel pump cover screw 4 35

Page 3C-42 90-883064R02 JULY 2006

 Service Procedures

6. Inspect the O-ring, and replace if necessary. Install onto the fuel pump assembly.

a
53620

a - O-ring

90-883064R02 JULY 2006 Page 3C-43

Service Procedures

Installation
1. Secure the fuel pump, and cowl deflector to the cylinder head cover with screws.
Tighten to the specified torque.
2. Connect the fuel lines to the pump, and secure with new cable ties.

c
h

a b

j
b

c a e
66

g d

f
e

d 58974

a - Inlet fuel hose from fuel filter

b - Outlet fuel hose to VST
c - Fuel cooler water inlet hose from VST fuel cooler
d - Fuel cooler water outlet hose to tell-tale outlet
e - Mounting screw (2) (M6 x 30)
f - Cowl deflector
g - Fuel pump
h - Conduit (33 cm [13 in.])
i - Conduit (53 cm [21 in.])
j - Cable tie
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

66 Loctite 242 92-809821 92-809821

Description Nm lb. in. lb. ft.

Fuel pump mounting screw 8.5 75

Page 3C-44 90-883064R02 JULY 2006

 Service Procedures

Fuel Filter
Disassembly
1. Unscrew the fuel filter cup, and remove the fuel filter element, and O-rings.
2. Inspect the O-rings, and replace if necessary.
3. Clean the fuel filter cup, and replace the fuel filter element if needed.
Assembly
1. Lubricate the O-rings, and install the fuel filter element.
2. Install the fuel filter cup, and hand-tighten.

a b

a - Fuel filter assembly

b - Fuel filter cap
c - Fuel filter element
d - O-ring
e - Fuel filter cup
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

90-883064R02 JULY 2006 Page 3C-45

Service Procedures

Vapor Separator (VST) S/N 1B036613 And Below

WARNING
Always release the fuel pressure in the high pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel
may spray out.
Removal
1. Release the fuel pressure. Refer to Releasing Fuel Pressure in the High Pressure
Fuel Line.
2. Remove the lower cowl. Drain the fuel from the VST into a suitable container.
3. Disconnect the fuel lines, water lines, and high pressure fuel pump harness connector.
4. Remove the VST mounting screws, and remove the VST from the engine.
g
c

66

e a

b
f

58986

a - VST drain valve

b - VST drain hose
c - Fuel hose - Mechanical fuel pump to VST
d - High pressure fuel hose - Fuel cooler to fuel distribution manifold
e - Water hose - VST fuel cooler to mechanical fuel pump fuel cooler
f - Water hose - Exhaust cover to fuel cooler
g - VST vent hose
h - High pressure fuel pump harness connector
i - Vapor separator mounting screws (3) (M6 x 25)
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

66 Loctite 242 92-809821 92-809821

Page 3C-46 90-883064R02 JULY 2006

 Service Procedures

Disassembly
1. Remove the fuel cooler mounting screw.
2. If the removal of the fuel cooler is required because of damaged/plugged hoses or fuel
cooler replacement, cut the metal hose clamps, and remove the fuel hoses from the
VST cover. Remove the fuel cooler.
3. Remove the VST cover screws, and remove the cover assembly.

c
d

e
c

a - Fuel cooler mounting screw (1) (M6 x 25)

b - Fuel cooler
c - Metal hose clamp
d - VST cover screws (5)
e - VST cover assembly

90-883064R02 JULY 2006 Page 3C-47

Service Procedures

4. Disconnect the high pressure fuel pump connectors, and remove the high pressure
fuel pump.
5. Inspect, and clean the high pressure fuel pump screen.

a - Connectors
b - High pressure fuel pump
c - Screen

6. Loosen the float pin retaining screw, and remove the float assembly.
7. Remove the baffle plate (if desired).
8. Remove, and inspect the seat.
9. Inspect, and clean the VST float chamber.

g a

e
c

d
f

b
i
h
a - Float pin retaining screw
b - Float
c - Float shaft
d - Clip
e - Needle
f - Baffle plate
g - VST float chamber
h - Seat
i - Gasket

Page 3C-48 90-883064R02 JULY 2006

 Service Procedures

Assembly
1. Apply Loctite 242 to the screws, and install the baffle plate (if removed). Tighten the
screws to the specified torque.
2. Install the seat with the new gasket, and tighten securely.
3. Install the float assembly as shown. Install the float pin, and tighten the retaining screw
to specified torque.

a
66

f
e
c
d

b
h
g
a - Float pin retaining screw e - Needle
b - Float f - Baffle plate screw (3)
c - Float shaft g - Seat
d - Clip h - Gasket
Tube Ref. Quicksilver Part
Description Mercury Part Number
No. Number

66 Loctite 242 92-809821 92-809821

Description Nm lb. in. lb. ft.

Float pin retaining screw 2.5 22
Baffle plate screw (3) 2.5 22
4. Connect the high pressure fuel pump connectors. Push the nozzle into the rubber
grommet (lubricate with light oil if necessary). Make sure the alignment pin is positioned
properly, and lines up with the hole in the high pressure fuel pump.

a
c

a - Connectors
b - High pressure fuel pump
c - Alignment pin
Tube Ref. Quicksilver Part
Description Mercury Part Number
No. Number

110 4-Stroke 10W-30 Outboard Oil 92-802833A1 92-802833Q1

90-883064R02 JULY 2006 Page 3C-49

Service Procedures

5. Install the grommet to the bottom of the high pressure fuel pump.
6. Lightly clamp the VST float chamber in a vise. Position the VST cover assembly so the
high pressure fuel pump is horizontal. This will prevent the grommet from falling off.
7. Install the VST cover assembly, and new gasket, into float chamber. Push the cover,
and float chamber together, this will compress the grommet, and allow the screws to
be threaded in.
8. Install the VST cover screws, and tighten to the specified torque.
9. Install the new hose clamps onto the fuel hoses. Crimp the hose clamps with the
appropriate tool.

g
e
g
d

h
a
i

c
j

a - Grommet
b - Gasket
c - VST float chamber
d - High pressure fuel pump
e - VST cover assembly
f - VST cover screws (5)
g - Metal hose clamp (4)
h - Fuel cooler mounting screw (1) (M4 x 20)
i - Fuel cooler
j - Hose Clamp Tool 91-803146T
Hose Clamp Tool 91-803146T

Description Nm lb. in. lb. ft.

VST cover screws (5) 3.5 32

Page 3C-50 90-883064R02 JULY 2006

 Service Procedures

Installation
1. Tighten the drain valve, and install the VST to the engine. Tighten the mounting screws
to the specified torque.
2. Connect the fuel and water hoses as shown below. Secure with cable ties.
3. Plug in the high pressure fuel pump harness connector.
g
c

66

e a

b
f

58986

a - VST drain valve

b - VST drain hose
c - Fuel hose - Mechanical fuel pump to VST
d - High pressure fuel hose - Fuel cooler to fuel distribution manifold
e - Water hose - VST fuel cooler to mechanical fuel pump fuel cooler
f - Water hose - Exhaust cover to fuel cooler
g - VST vent hose
h - High pressure fuel pump harness connector
i - Vapor separator mounting screws (3) (M6 x 25)
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

66 Loctite 242 92-809821 92-809821

Description Nm lb. in. lb. ft.

Vapor separator mounting screw 5 45
Drain valve 5.6 - 11.3 50 - 100

90-883064R02 JULY 2006 Page 3C-51

Service Procedures

Vapor Separator (VST) S/N 1B036614 And Above

Removal
1. Release the fuel pressure. Refer to Releasing Fuel Pressure in the High Pressure
Fuel Line.
2. Remove the lower cowl. Drain the fuel from the VST into a suitable container.
3. Disconnect the fuel lines, water lines, and high pressure fuel pump harness connector.
4. Remove the VST mounting screws, and remove the VST from the engine.
g
c

66

e a

b
f

58986

a - VST drain valve

b - VST drain hose
c - Fuel hose - Mechanical fuel pump to VST
d - High pressure fuel hose - Fuel cooler to fuel distribution manifold
e - Water hose - VST fuel cooler to mechanical fuel pump fuel cooler
f - Water hose - Exhaust cover to fuel cooler
g - VST vent hose
h - High pressure fuel pump harness connector
i - Vapor separator mounting screws (3) (M6 x 25)
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

66 Loctite 242 92-809821 92-809821

Disassembly
1. Remove the fuel cooler mounting screw.
2. If the removal of the fuel cooler is required, cut the metal hose clamps, and remove
the fuel hoses from the VST cover. Remove the fuel cooler.

Page 3C-52 90-883064R02 JULY 2006

 Service Procedures

3. Remove the VST cover screws, and remove the cover assembly.
b c
a

d
j
e
f
g
l
h
i

7624

a - VST cover screws

b - Electrical connector
c - Fuel inlet
d - VST cover assembly
e - High pressure fuel pump
f - Adapter
g - Gasket
h - Screen
i - O-ring
j - VST float chamber
k - Fuel outlet
l - Fuel cooler

90-883064R02 JULY 2006 Page 3C-53

Service Procedures

4. Disconnect the high pressure fuel pump connectors, and remove the high pressure
fuel pump.
5. Inspect, and clean the high pressure fuel pump screen.

b e
d
c
7522

a - Connector insulator (connectors underneath)

b - High pressure fuel pump
c - Screen
d - Fuel pressure regulator hose
e - Hose clamp

6. Loosen the float pin retaining screw, and remove the float assembly.
7. Remove the fuel pressure regulator retaining screw.
8. Remove the fuel pressure regulator.

b
c d 7574

a - Float pin retaining screw

b - Float
c - Grommet
d - Fuel pressure regulator retaining screw
e - Fuel pressure regulator

9. Inspect, and clean the VST float chamber.

10. Inspect the fuel inlet seat for damage.
NOTE: The fuel inlet seat is not serviceable.
11. Remove the three screws securing the baffle plate, and remove the baffle plate.

Page 3C-54 90-883064R02 JULY 2006

 Service Procedures

12. Inspect, and clean the regulator screen.

13. Remove the electrical connector. Depress the three locking tabs, and push the
connector out of the top cover.

e
b
a

d
7611

a - Fuel inlet seat

b - Electrical connector locking tab (3)
c - Screen - regulator
d - Fuel pump grommet
e - Threaded hole for baffle plate
Assembly
1. Install the electrical connector in the VST cover.
2. Apply Loctite 242 to the screw, and install the pressure regulator.
3. Install the hose to the pressure regulator valve. Secure with a hose clamp.
4. Install the high pressure pump grommet.
5. Apply Loctite 242 to the screws, and install the baffle plate (if removed). Tighten screws
to the specified torque.

90-883064R02 JULY 2006 Page 3C-55

Service Procedures

6. Install the float pin screws loosely.

a
j b

i
c

h d
66

g e

f
7646

a - Electrical connector
b - Cover
c - Grommet
d - Pressure regulator
e - Hose clamp
f - Hose assembly
g - Pressure regulator retaining screw
h - Baffle plate screws (3)
i - Float pin retaining screws (2)
j - Baffle plate
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

66 Loctite 242 92-809821 92-809821

Description Nm lb. in. lb. ft.

Pressure regulator, and baffle plate screw 2.5 22

7. Assemble the filter, and grommet to the high pressure fuel pump.
8. Inset the high pressure fuel pump through the cable tie.
9. Connect the high pressure fuel pump electrical wires.
10. Push the insulator over the wire connectors. Ensure the slot on the insulator fits on the
fin on the cover.
11. Install the float pin through the hole in the float.
12. Assemble the float assembly under the float retainer screws as the float fuel shut off
needle is installed in the seat.

Page 3C-56 90-883064R02 JULY 2006

 Service Procedures

13. Tighten the float pin retaining screws to the specified torque.

j
h
b
i

c
g
f d
e
8046

a - Fuel pump electrical wires

b - Insulator
c - Cable tie
d - High pressure fuel pump
e - Filter
f - Grommet
g - Float
h - Float pin
i - Grommet
j - Fuel inlet seat
Description Nm lb. in. lb. ft.
Float pin retaining screw 2.5 22

14. Install the grommet to the bottom of the high pressure fuel pump.
15. Install the O-ring seal in the groove on the VST float chamber.
16. Assemble the float chamber to the upper VST assembly.
17. Assemble the fuel cooler to the VST fuel hoses.
18. Secure the VST cover assembly to the float chamber with five screws. Tighten the
screws to the specified torque.
19. Install the new hose clamps to the VST fuel hoses. Use the hose clamp tool
(91-803146T) to secure the hose clamp.

90-883064R02 JULY 2006 Page 3C-57

Service Procedures

20. Install the fuel cooler mounting screw. Tighten the screw to the specified torque.
b c
a

d
j
e
f
g
l
h
i

91-803146T
7624

a - VST cover screws

b - Electrical connector
c - Fuel inlet
d - VST cover assembly
e - High pressure fuel pump
f - Adapter
g - Gasket
h - Screen
i - O-ring
j - VST float chamber
k - Fuel outlet
l - Fuel cooler
Hose Clamp Tool 91-803146T

Description Nm lb. in. lb. ft.

VST mounting screw 2.5 22
Fuel cooler mounting screw 3.5 32

Page 3C-58 90-883064R02 JULY 2006

 Service Procedures

Installation
1. Tighten the drain valve, and install the VST to the engine. Tighten the mounting screws
to the specified torque.
2. Connect the fuel and water hoses as shown below. Secure with cable ties.
3. Plug in the high pressure fuel pump harness connector.
g
c

66

e a

b
f

58986

a - VST drain valve

b - VST drain hose
c - Fuel hose - Mechanical fuel pump to VST
d - High pressure fuel hose - Fuel cooler to fuel distribution manifold
e - Water hose - VST fuel cooler to mechanical fuel pump fuel cooler
f - Water hose - Exhaust cover to fuel cooler
g - VST vent hose
h - High pressure fuel pump harness connector
i - Vapor separator mounting screws (3) (M6 x 25)
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

66 Loctite 242 92-809821 92-809821

Description Nm lb. in. lb. ft.

Vapor separator mounting screw 5 45
Drain valve 5.6 - 11.3 50 - 100

90-883064R02 JULY 2006 Page 3C-59

Service Procedures

Pressure Regulator Removal/Installation

1B036613 And Below
WARNING
Always release the fuel pressure in the high pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel
may spray out.
NOTE: The pressure regulator vent is an open fitting that does not require a hose to be
attached.

REMOVAL
1. Release the fuel pressure. Refer to Releasing Fuel Pressure in the High Pressure
Fuel Line.
2. Remove the fuel pressure regulator mounting screws, and remove the regulator from the
VST cover.
3. Inspect the O-rings. Replace if necessary. Inspect, and clean the screen.

INSTALLATION
1. Lubricate the O-rings with light lubricant, and reassemble the pressure regulator to the
VST cover.
2. Apply Loctite 242 to the mounting screws, and tighten to the specified torque.

a
d
b
66
c

a - Mounting screw (2)

b - Fuel pressure regulator
c - O-rings
d - Vent
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil
66 Loctite 242 92-809821 92-809821

Description Nm lb. in. lb. ft.

Pressure regulator mounting screw 2.5 22

Page 3C-60 90-883064R02 JULY 2006

 Service Procedures

High Pressure Fuel Line Removal/Installation

WARNING
Always release the fuel pressure in the high-pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel
may spray out.

Removal
1. Disconnect the fuel line from the fuel distribution manifold by depressing the locking
tab.
2. Disconnect the fuel line from the fuel cooler by depressing the locking tab.
3. Remove the high pressure fuel line assembly.
4. Inspect the filter for cracks/debris. Replace if necessary.

Installation
1. Connect the fuel lines as shown.

f
a

a - Locking tab
b - Fuel filter
c - Fuel line (to VST fuel cooler)
d - Fuel line (to fuel distribution manifold)
e - Protective sleeve
f - Conduit
g - Conduit

90-883064R02 JULY 2006 Page 3C-61

 Emissions

Electronic Fuel Injection

Section 3D - Emissions
Table of Contents
Exhaust Emissions Standards . . . . . . . . . . . . 3D-2 Manufacturer’s Responsibility . . . . . . . . . 3D-4
What Are Emissions? . . . . . . . . . . . . . . . . 3D-2 Dealer Responsibility . . . . . . . . . . . . . . . . 3D-4
Hydrocarbons -- HC . . . . . . . . . . . . . . . . . . 3D-2 Owner Responsibility . . . . . . . . . . . . . . . . 3D-4
Carbon Monoxide -- CO . . . . . . . . . . . . . . 3D-2 EPA Emission Regulations . . . . . . . . . . . . 3D-5
Oxides of Nitrogen - NOx . . . . . . . . . . . . .
Controlling Emissions . . . . . . . . . . . . . . . .
3D-2
3D-2
Decal Location . . . . . . . . . . . . . . . . . . . . . .
Service Replacement Certification Label . . .
3D-7
3D-7
3
Stoichiometric (14.7:1) Air/Fuel Ratio . . . 3D-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-7 D
Outboard Hydrocarbon Emissions Date Code Identification . . . . . . . . . . . . . . 3D-7
Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-8
8-1/3% ⇓ Per Year Over 9 Model Years . 3D-3 Decal Location . . . . . . . . . . . . . . . . . . . . . . 3D-8
Emissions Information . . . . . . . . . . . . . . . . . . 3D-4

90-883064R02 JULY 2006 Page 3D-1

Emissions

Exhaust Emissions Standards

Through the Environmental Protection Agency (EPA), the federal government has
established exhaust emissions standards for all new marine engines sold in the U.S.
What Are Emissions?
Emissions are what comes out of the exhaust system in the exhaust gas when the engine
is running. They are formed as a result of the process of combustion or incomplete
combustion. To understand exhaust gas emissions, remember that both air, and fuel are
made of several elements. Air contains oxygen, and nitrogen among other elements;
gasoline contains mainly hydrogen, and carbon. These four elements combine chemically
during combustion. If combustion were complete, the mixture of air, and gasoline would
result in these emissions: water, carbon dioxide, and nitrogen, which are not harmful to the
environment. But combustion is not usually complete. Also, potentially harmful gases can
be formed during, and after combustion.
All marine engines must reduce the emission of certain pollutants, or potentially harmful
gases, in the exhaust to conform with levels legislated by the EPA. Emissions standards
become more stringent each year. Standards are set primarily with regard to three
emissions: hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx).
Hydrocarbons - HC
Gasoline is a hydrocarbon fuel. The two elements of hydrogen, and carbon are burned
during combustion in combination with oxygen. But they are not totally consumed. Some
pass through the combustion chamber, and exit the exhaust system as unburned gases
known as hydrocarbons.
Carbon Monoxide - CO
Carbon is one of the elements that make up the fuel burned in the engine along with oxygen
during the combustion process. If the carbon in the gasoline could combine with enough
oxygen (one carbon atom with two oxygen atoms), it would come out of the engine in the
form of carbon dioxide (CO2). CO2 is a harmless gas. But carbon often combines with
insufficient oxygen (one carbon atom with one oxygen atom). This forms carbon monoxide
(CO). Carbon monoxide is the product of incomplete combustion, and is a dangerous,
potentially lethal gas.
Oxides of Nitrogen - NOx
NOx is a slightly different byproduct of combustion. Nitrogen is one of the elements that
makes up the air going into the engine. Under extremely high temperatures it combines
with oxygen to form oxides of nitrogen (NOx). This happens in the engine’s combustion
chambers when temperatures are too high. NOx itself is not harmful, but when exposed
to sunlight it combines with unburned hydrocarbons to create the visible air pollutant
known as smog. Smog is a serious problem in California as well as many other heavily
populated areas of the United States.
Controlling Emissions
There are two principle methods of reducing emissions. The first method is to control the
air/fuel ratio that goes into the combustion chamber. The second is to control the time when
this air/fuel mixture enters the combustion chamber.

Page 3D-2 90-883064R02 JULY 2006

 Emissions

Stoichiometric (14.7:1) Air/Fuel Ratio

In the search to control pollutants, and reduce exhaust emissions, engineers have
discovered that they can be reduced effectively if a gasoline engine operates at an air/fuel
ratio of 14.7:1. The technical term for this ideal ratio is stoichiometric. An air/fuel ratio of
14.7:1 provides the best control of all three elements in the exhaust under almost all
conditions.
The HC, and CO content of the exhaust gas is influenced significantly by the air/fuel ratio.
At an air/fuel ratio leaner than 14.7:1, HC, and CO levels are low, but with a ratio richer than
14.7:1 they rise rapidly. It would seem that controlling HC, and CO by themselves might
not be such a difficult task; the air/fuel ratio only needs to be kept leaner than 14.7:1.
However, there is also NOx to consider.
As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher
combustion temperatures raise the NOx content of the exhaust. But, enrichening the
air/fuel ratio to decrease combustion temperatures, and reduce NOx also increases HC,
and CO, as well as lowering fuel economy. So the solution to controlling NOx, as well as
HC, and CO is to keep the air/fuel ratio as close to 14.7:1 as possible.

Outboard Hydrocarbon Emissions Reductions

8-1/3% ⇓ Per Year Over 9 Model Years

120

100

80

60

40

20

0
96 97 98 99 2000 01 02 03 04 05 06 07 08

90-883064R02 JULY 2006 Page 3D-3

Emissions

Emissions Information
Manufacturer’s Responsibility
Beginning with 1998 model year engines, manufacturers of all marine propulsion engines
must determine the exhaust emission levels for each engine horsepower family, and
certify these engines with the United States Environmental Protection Agency (EPA). A
certification decal/emissions control information label, showing emission levels, and
engine specifications directly related to emissions, must be placed on each engine at the
time of manufacture.
Dealer Responsibility
When performing service on all 1998 and later outboards that carry a certification,
attention must be given to any adjustments that are made that affect emission levels.
Adjustments must be kept within published factory specifications.
Replacement or repair of any emission related component must be executed in a manner
that maintains emission levels within the prescribed certification standards.
Dealers are not to modify the engine in any manner that would alter the horsepower or
allow emission levels to exceed their predetermined factory specifications.
Exceptions include manufacturers prescribed changes, such as that for altitude
adjustments.
Owner Responsibility
The owner/operator is required to have engine maintenance performed to maintain
emission levels within prescribed certification standards.
The owner/operator is not to modify the engine in any manner that would alter the
horsepower or allow emission levels to exceed their predetermined factory specifications.
Exceptions:
• Single engine exceptions may be allowed with permission from the EPA for racing,
and testing.

Page 3D-4 90-883064R02 JULY 2006

 Emissions

EPA Emission Regulations

All new 1998 and later outboards manufactured by Mercury Marine are certified to the
United States Environmental Protection Agency as conforming to the requirements of the
regulations for the control of air pollution from new outboard motors. This certification is
contingent on certain adjustments being set to factory standards. For this reason, the factory
procedure for servicing the product must be strictly followed, and whenever practicable,
the product must be returned to the original intent of the design.
The responsibilities listed above are general, and in no way a complete listing of the rules
and regulations pertaining to the EPA laws on exhaust emissions for marine products. For
more detailed information on this subject, you may contact the following locations:
VIA U.S. POSTAL SERVICE:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
401 M St. NW
Washington, DC 20460
VIA EXPRESS or COURIER MAIL:
Office of Mobile Sources
Engine Programs and Compliance Division
Engine Compliance Programs Group (6403J)
501 3rd St. NW
Washington, DC 20001
EPA INTERNET WEB SITE:
http:/www.epa.gov/omswww

90-883064R02 JULY 2006 Page 3D-5

Emissions

CERTIFICATION LABEL
The certification label must be placed on each engine at the time of manufacture, and must
be replaced in the same location if damaged or removed. Shown below is a typical
certification label, and is not representative of any one model. Label shown below is not
to scale; shown at twice the normal size.

EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO 2002 CALIFORNIA AND U.S. EPA
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE.
i IDLE SPEED (IN GEAR): 725 ± 25 RPM FAMILY: 2M9XM.7472G0 a
h 30 HP 747 cc FEL: 18.0 g/kW-hr b
g
TIMING (IN DEGREES): NOT ADJUSTABLE c

f Spark Plug: NGK DPR6EA-9

JAN 2001 Gap: 1.0 mm (0.035″) d

Cold Valve Clearance (mm) Intake: 0.15 -- 0.25

Exhaust: 0.25 -- 0.35 e

a - Family example
b - FEL: Represents (Mercury Marine) statement of the maximum emissions out-
put for the engine family
c - Timing specifications when adjustable
d - Recommended spark plug for the best engine performance
e - Valve clearance (4 Stroke engines only)
f - Date of manufacture
g - Cubic centimeter
h - Engine horsepower rating
i - Idle speed (In gear)
1 M9X M. 747 2 G 0
E=EFI fuel system
0=Unspecified
3=Ultra Clean California rated eng.
Model Year Regulation
1=2001 M=Marine Technology type
1=Existing
Application
Manufacturer 2=New
C=2 Stroke
Mercury Marine 3=Sport Jet
E=EFI Sport Jet
Displacement G=4 Stroke
Liter H=Hi-Perf.
Cubic inch J=Sport Jet

Page 3D-6 90-883064R02 JULY 2006

 Emissions

Decal Location
Model Year Service Part No. Location on Engine
2002 Merc/Mar 747 cc 37-883927AO2 Flywheel/rewind cover
2003 Merc/Mar 747 cc 37-883927AO3 Flywheel/rewind cover
2004 Merc/Mar 747 cc 37-883927AO4 Flywheel/rewind cover
2005 Merc/Mar 747 cc 37-883927AO5 Flywheel/rewind cover

Service Replacement Certification Label

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

EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO 2002 CALIFORNIA AND U.S. EPA
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE.
IDLE SPEED (IN GEAR): 725 ± 25 RPM FAMILY: 2M9XM.7472G0
30 HP 747 cc FEL: 18.0 g/kW-hr
TIMING (IN DEGREES): NOT ADJUSTABLE
Spark Plug: NGK DPR6EA-9
Gap: 1.0 mm (0.035″)

Cold Valve Clearance (mm) Intake: 0.15 -- 0.25

Exhaust: 0.25 -- 0.35
b JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC

a
a - V notch
b - Month of manufacture

90-883064R02 JULY 2006 Page 3D-7

Emissions

Installation
Install the label on a clean surface in the original factory location.
Decal Location
Model Service Part No. Location on Engine
2002 Merc/Mar 747 cc 37-883927AO2 Flywheel/rewind cover

Page 3D-8 90-883064R02 JULY 2006

 Cylinder Head

Powerhead
Section 4A - Cylinder Head
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2 Valve Removal . . . . . . . . . . . . . . . . . . . . . . . 4A-26
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3 Rocker Shaft and Rocker Arm . . . . . . . . . . 4A-27
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-6 Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 4A-28
Camshaft/Oil Pump . . . . . . . . . . . . . . . . . . . . . . 4A-8 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-28
Intake/Exhaust Valves . . . . . . . . . . . . . . . . . . . 4A-10 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 4A-30
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4A-12 Valve Guide inspection . . . . . . . . . . . . . . . . 4A-30
Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13 Valve Guide Replacement . . . . . . . . . . . . . 4A-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-15
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . .
4A-32
4A-33
4
Valve Clearance Adjustment . . . . . . . . . . . . . . 4A-18 Valve Seat Reconditioning . . . . . . . . . . . . . 4A-35 A
Checking Valve Clearance . . . . . . . . . . . . . 4A-18 Valve Refacing Steps . . . . . . . . . . . . . . . . . 4A-36
Adjusting Valves . . . . . . . . . . . . . . . . . . . . . 4A-19 Cylinder Head Reassembly . . . . . . . . . . . . . . . 4A-37
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-20 Valve Installation . . . . . . . . . . . . . . . . . . . . . 4A-37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-20 Camshaft Oil Seal Installation . . . . . . . . . . 4A-38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-20 Camshaft Installation . . . . . . . . . . . . . . . . . 4A-39
Cylinder Head Removal . . . . . . . . . . . . . . . . . . 4A-21 Oil Pump Installation . . . . . . . . . . . . . . . . . . 4A-40
Cylinder Head Disassembly . . . . . . . . . . . . . . 4A-24 Rocker Arm Shaft Assembly . . . . . . . . . . . 4A-40
Rocker Arm Assembly Removal . . . . . . . . 4A-24 Rocker Arm Shaft Installation . . . . . . . . . . 4A-41
Oil Pump Removal . . . . . . . . . . . . . . . . . . . 4A-24 Cylinder Head Gasket . . . . . . . . . . . . . . . . . 4A-42
Camshaft Removal . . . . . . . . . . . . . . . . . . . 4A-25 Cylinder Head Installation . . . . . . . . . . . . . . . . 4A-43

90-883064R02 JULY 2006 Page 4A-1

Cylinder Head

Special Tools
1. Flywheel Holder (P/N 91-83163M)

2. Valve Guide Remover (P/N 91-809495A1)

3. Valve Guide Installer Bushing (P/N 91-809496A1)

4. Valve Guide Reamer (P/N 91-809497A1)

5. Valve Spring Compressor (P/N 91-809494A1)

6. Valve Seat Cutter Kit (Obtain Locally)

Page 4A-2 90-883064R02 JULY 2006

 Cylinder Head

Specifications
Camshaft Dimensions
Intake A
Exhaust A
Intake B A
Exhaust B

B
Runout Limit
Camshaft Bearing Diameter “b” 30.83 - 31.03 mm (1.214 - 1.222 in.)
30.83 - 31.03 mm (1.214 - 1.222 in.)
25.90 - 26.10 mm (1.020 - 1.028 in.)
25.90 - 26.10 mm (1.020 - 1.028 in.)
Camshaft

b b 0.1 mm (0.0039 in.)

36.935 - 36.955 mm
(1.4541 - 1.4549 in.)
b
b

Free Length “a” 37.85 - 39.85 mm (1.491 - 1.569 in.)

Tilt Limit “b” Less than 1.7 mm (0.060 in.)
bb

Valve Spring aa

Compressed Pressure (Installed) 9.0 - 10.0 kg (19.8 - 22.0 lbs.)

Intake 9.0 - 10.0 kg (19.8 - 22.0 lbs.)
Exhaust 1.1 mm (0.043 in.)
Tilt Limit (Intake & Exhaust)

90-883064R02 JULY 2006 Page 4A-3

Cylinder Head

Warp Limit

0.1 mm (0.004 in.)

56899

Cylinder Head
Camshaft Bore Inside Diameter “a”

a
a 37.000 - 37.025 mm
(1.4567 - 1.4577 in.)
a

56900

Valve/Valve Seat/Valve Guides:

Valve Clearance (cold)
Intake
Exhaust
Valve Dimensions:
A Head Diameter 0.15 - 0.25 mm (0.006 - 0.010 in.)
Intake 0.25 - 0.35 mm (0.010 - 0.014 in.)
Exhaust
B Face Width
Intake 31.9 - 32.1 mm (1.256 - 1.264 in.)
Exhaust 25.9 - 26.1 mm (1.020 - 1.028 in.)
C Seat Width
Intake 2.00 - 3.14 mm (0.079 - 0.124 in.)
Exhaust 2.00 - 3.14 mm (0.079 - 0.124 in.)
D Margin Thickness
Intake 0.9 - 1.1 mm (0.035 - 0.043 in.)
Valves Exhaust 0.9 - 1.1 mm (0.035 - 0.043 in.)
Stem Outside Diameter
Intake 0.5 - 0.9 mm (0.020 - 0.035 in.)
Exhaust 0.5 - 0.9 mm (0.020 - 0.035 in.)
Guide Inside Diameter
Intake 5.475 - 5.490 mm (0.2156 - 0.2161 in.)
Exhaust 5.460 - 5.475 mm (0.2150 - 0.2156 in.)
Stem To Guide Clearance
Intake 5.500 - 5.512 mm (0.2165 - 0.2170 in.)
Exhaust 5.500 - 5.512 mm (0.2165 - 0.2170 in.)
Stem Runout Limit (max.)
0.010 - 0.037 mm (0.0004 - 0.0015 in.)
0.025 - 0.052 mm (0.0010 - 0.0020 in.)
0.016 mm (0.0006 in.)

Page 4A-4 90-883064R02 JULY 2006

 Cylinder Head

Valve Dimensions

B C

D
A

Rocker Shaft Outside Diameter 15.971 - 15.991 mm

(0.6288 - 0.6296 in.)

Rocker Arm Inside Diameter of Bore 16.000 - 16.018 mm

(0.6299 - 0.6306 in.)

90-883064R02 JULY 2006 Page 4A-5

Cylinder Head

Cylinder Head

Page 4A-6 90-883064R02 JULY 2006

 Cylinder Head

Cylinder Head
Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
1 Cylinder head (Electric)
–
1 Cylinder head (Manual)
1 1 Cylinder head
2 6 Guide
3 3 Screw (M6 x 8) 6.0 57
4 3 Gasket
5 1 Oil seal
6 5 Pipe plug
7 1 O-ring
8 1 Cover
9 1 Breather pipe
10 1 Decal - Servicing referral
11 1 Decal - Engine oil/valve clearance
12 8 Screw (M9 x 1.5 x 95) 47 35.0
13 4 Screw (M6 x 25) 12 106
14 1 Gasket
15 7 Screw (M6 x 20) 8 70
16 1 Baffle plate
17 4 Screw (M4 x 10)
18 1 Elbow
19 1 Bracket (Handle)
20 2 Screw (M6 x 13) (Handle)
21 1 Plug
22 1 O-ring
1 Decal - HP ID (30)
23
1 Decal - HP ID (40)
24 2 Dowel pin

Tube Ref. Description Mercury Part Number Quicksilver Part

No. Number

110 4-Stroke 10W-30 Outboard Oil 92-802833A1 92-802833Q1

90-883064R02 JULY 2006 Page 4A-7

Cylinder Head

Camshaft/Oil Pump
1

3
4

7
110
6

8
110

10
9
12 11

13

51

Page 4A-8 90-883064R02 JULY 2006

 Cylinder Head

Camshaft/Oil Pump
Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
1 1 Screw (M8 x 40 x 1.25) 38 28
2 1 Washer
3 1 Belt
4 1 Gear - driven
5 1 Dowel pin
6 1 Camshaft (Manual)
7 1 Camshaft (Electric)
8 1 Pin
9 1 Oil pump assembly
10 1 O-ring
11 1 O-ring
12 1 O-ring
13 4 Screw (M6 x 35) 8 70

Tube Ref. Description Mercury Part Number Quicksilver Part

No. Number

110 4-Stroke 10W-30 Outboard Oil 92-802833A1 92-802833Q1

51 Loctite 222 92-809818 92-809818

90-883064R02 JULY 2006 Page 4A-9

Cylinder Head

Intake/Exhaust Valves
110
7

4 5 6

3 9
8
1
8
9
7

6
110 5

12 18
4 16
11 17
110

3
110

14
10
2

13

19

15

11

Page 4A-10 90-883064R02 JULY 2006

 Cylinder Head

Intake/Exhaust Valves
Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
1 3 Exhaust valve
2 3 Intake valve
3 6 Seal - Valve stem
4 6 Valve spring - Outer
5 6 Retainer - Valve spring
6 12 Cotter key
7 6 Rocker arm
8 6 Screw
9 6 Nut 13.5 120 10
10 1 Rocker shaft
11 2 Plug
12 1 Bracket
13 1 Spring
14 1 Bracket
15 1 Spring
16 1 Seal cup
17 1 Pin - Cam thrust
18 4 Screw (M8 x 23) 18 160 13.3
19 2 Spring

Tube Ref. Description Mercury Part Number Quicksilver Part

No. Number

110 4-Stroke 10W-30 Outboard Oil 92-802833A1 92-802833Q1

90-883064R02 JULY 2006 Page 4A-11

Cylinder Head

Torque Sequence
7 6
8
4

4
2
3
3 4

1
1 2
1
2
5

3
6
5

Description Nm lb. in. lb. ft.

Intake manifold screw 8 70
Cylinder head center screw (8) First 23 17
Cylinder head center screw (8) Second 47 35
Cylinder head flange screw (4) First 6 53
Cylinder head flange screw (4) Second 12 106

Page 4A-12 90-883064R02 JULY 2006

 Cylinder Head

Valve Cover
Removal
1. Disconnect spark plug leads, and remove spark plugs.
2. Remove flywheel cover.
3. Remove lower cowl for easier access to lower screws (optional).

a - Screw (4) (M6 x 25)

b - Flywheel cover

90-883064R02 JULY 2006 Page 4A-13

Cylinder Head

4. Disconnect the crankcase breather hose and vent hose, the fuel pump input/output
hose, and the fuel cooler in/out hoses.
5. Remove the fuel pump from the valve cover.

WARNING
Always release the fuel pressure in the high pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel may
spray out.
6. Disconnect the high pressure fuel line from the fuel distribution manifold by depressing
the locking tab. Refer to Section 3C - Releasing Fuel Pressure in the High Pressure
Fuel Line.
7. Remove the coil plate fasteners, and swing the coil plate assembly to the side.
8. Loosen the water separating fuel filter nut, pull the assembly from the mounting bracket,
and place it out of the way.
9. Remove the valve cover.
c

h
g

e a

b
j
i
d
f

58974

a - Crankcase breather hose

b - Crankcase vent hose
c - Fuel pump output hose
d - Fuel pump input hose
e - Fuel cooler in hose
f - Fuel cooler out hose
g - Valve cover
h - Screw (7) (M6 x 20)
i - Coil plate screw and washer (3) (M6 x 30)
j - Fuel pump
k - Water separating fuel filter

Page 4A-14 90-883064R02 JULY 2006

 Cylinder Head

Installation
1. Install the valve cover seal into the groove.
2. If removed, reinstall the baffle plate. Tighten the screws securely.

a - Baffle plate
b - Screw (4) (M4 x 10)
c - Cover seal

90-883064R02 JULY 2006 Page 4A-15

Cylinder Head

3. Reinstall the valve cover. Tighten the screws to the specified torque.
4. Install the water separating fuel filter onto the bracket, and tighten the nut.
5. Install the coil plate. Install the screws, and washers. Tighten the screws to the specified
torque. Ensure the coil ground wires are secured with screws.
6. Install the fuel pump. Refer to Section 3C - Fuel Pump Installation.
7. Connect the fuel pump in/out hoses, fuel cooler in/out hoses, crankcase breather and
vent hose. Secure all with cable ties. Connect the high pressure fuel line to the fuel
distribution manifold.
8. Reinstall the spark plugs, and spark plug leads.
c

h
g

e a l

b
j
i
d
f

58974

a - Crankcase breather hose

b - Crankcase vent hose
c - Fuel pump outlet hose
d - Fuel pump inlet hose
e - Fuel cooler in hose
f - Fuel cooler out hose
g - Valve cover
h - Screw (7) (M6 x 20)
i - Coil plate screw and washer (3) (M6 x 30)
j - Fuel pump
k - Water separating fuel filter
l - Coil ground wire (2)
Description Nm lb. in. lb. ft.
Valve cover screw 8 70
Coil mount plate screw 8.5 75

Page 4A-16 90-883064R02 JULY 2006

 Cylinder Head

9. Install the flywheel cover.

a - Flywheel cover
b - Screw (4) (M6 x 25)
Description Nm lb. in. lb. ft.
Flywheel cover screw 8.5 75

90-883064R02 JULY 2006 Page 4A-17

Cylinder Head

Valve Clearance Adjustment

NOTE: The valve should be adjusted when the engine is cold.

WARNING
Engine could possibly start when turning the flywheel during adjustment. To
prevent this type of accidental engine starting, and possible serious injury, always
remove the spark plug leads from the spark plugs.

Checking Valve Clearance

1. Remove the valve cover. Refer to Valve Cover Removal.
2. Measure the valve clearance with a feeler gauge. Adjust if out of specification.
NOTE: When loosening the locknuts, hold the adjusting screw with a screwdriver to prevent
it from moving.

Valve clearance (cold)

Intake 0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust 0.25 - 0.35 mm (0.010 - 0.014 in.)

d c

a - Locknut
b - Adjusting screw
c - Intake valve clearance
d - Exhaust valve clearance

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 Cylinder Head

Adjusting Valves
1. Perform the following adjustment steps:
a. Turn the driven gear, and align the “1 or D” mark on the driven gear with the “D” mark
on the cylinder block.
b. Adjust the intake and exhaust valve clearance for cylinder #1.
c. Turn the driven gear 120° clockwise, and align the “∆” mark on the driven gear with
the “D” on the cylinder block.
d. Adjust the intake and exhaust valve clearance for cylinder #2.
e. Turn the driven gear 120° clockwise, and align the “D” mark on the driven gear with
the “∆” on the cylinder block.
f. Adjust the intake and exhaust valve clearance for cylinder #3.

d c

b
1

57191
a
a - Cylinder block “∆” mark
b - Driven gear “1 or ∆” mark - Cylinder #1
c - Driven gear “∆” mark at 120° - Cylinder #2
d - Driven gear “∆” mark at 240° - Cylinder #3

2. Tighten the locknuts.

NOTE: When tightening the locknuts, hold the adjusting screw with a screwdriver to prevent
it from moving.

Description Nm lb. in. lb. ft.

Valve adjusting locknut 13.5 120

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Cylinder Head

Timing Belt
Removal
1. Remove the flywheel, and the stator. Refer to Section 2B - Charging and Starting
System.
2. Remove the timing belt from the driven gear, and the drive gear.

a - Timing belt

Installation
Timing belt installation notes:
• Protect the timing belt from water, and oil.
• Use care not to scratch the belt.
• Do not use any metal device to help stretch the belt onto the driven gear.
1. Align marks on the drive, and driven gear with marks on the cylinder block as shown.
2. Install the timing belt onto the drive gear as shown. Numbers/letters on the belt should
be readable once the belt is installed.

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 Cylinder Head

3. Install the stator, and the flywheel. Refer to Section 2B - Charging & Starting System.

a d

c 1
b
c e

a - Drive gear mark

b - Driven gear mark
c - Cylinder block marks
d - Timing belt installed correctly
e - Timing belt installed incorrectly

Cylinder Head Removal

WARNING
Engine could possibly start when turning flywheel during adjustment. To prevent
this type of accidental engine starting, and possible serious injury, always remove
spark plug leads from spark plugs.
1. Remove the valve cover. Refer to Section 4 - Valve Cover Removal.
2. Remove the timing belt from the driven gear.

a - Timing belt
b - Driven gear

3. Remove the throttle and shift levers from the side of the cylinder head.

90-883064R02 JULY 2006 Page 4A-21

Cylinder Head

4. Remove the cylinder head, and intake manifold assembly mounting screws.
NOTE: The cylinder head gasket is not reusable.

c b

58981
d
a - Center screw (8) (M9 x 95)
b - Flange screw (4) (M6 x 25)
c - Intake manifold screw (6)
d - Throttle and shift levers

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 Cylinder Head

5. Separate the cylinder head from the cylinder block.

a - Gasket (discard)
b - Dowel pins (2)

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Cylinder Head

Cylinder Head Disassembly

Rocker Arm Assembly Removal
1. Remove the screws securing the rocker arm shaft to the cylinder head. Remove the
rocker arm assembly, and the retainers.

b
a

a - Screws (4) (M8 x 30)

b - Rocker arm assembly
Oil Pump Removal
1. Refer to Section 4C - Oil Pump Removal.

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 Cylinder Head

Camshaft Removal
1. Hold the driven gear using tool, and loosen the screw. Remove the screw, washer, driven
gear, and dowel pin.
NOTE: The camshaft can be removed from the top without removing the cylinder head from
the engine.

b
a

91-83163M

a - Holder
b - Driven gear
c - Screw (M8 x 40)
d - Washer
e - Dowel pin
Holder 91-83163M

2. Remove the camshaft retaining pin, and the seal.

3. Remove the oil seal, and the camshaft.
a

a - Oil seal
b - Camshaft
c - Camshaft retaining pin with seal

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Cylinder Head

Valve Removal
VALVE COMPONENTS

e
d
c
b
a
a - Valve
b - Valve seal
c - Valve spring
d - Spring retainer
e - Valve keepers

REMOVING VALVES
NOTE: Anytime a valve is removed, replace the valve seal.
1. Compress the valve springs using the valve spring compressor tool. Remove the valve
keepers, and the valves.

a - Valve spring compressor

b - Valve keepers
Valve Spring Compressor 91-809494A1

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 Cylinder Head

Rocker Shaft and Rocker Arm

1. Measure the rocker shaft diameter. Replace the shaft if not within specification.

Rocker shaft
Diameter 15.971 - 15.991 mm (0.6288 - 0.6296 in.)

2. Measure the rocker arm inside diameter. Replace the rocker arms if not within
specification.

55804

Rocker arm
Inside diameter 16.000 - 16.018 mm (0.6299 - 0.6306 in.)

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Cylinder Head

Cleaning/Inspection/Repair
Camshaft
Manual start models are equipped with a camshaft compression release mechanism.
The compression relief mechanism releases a percentage of the cylinder compression
during engine cranking, which lowers the starter rope pull force.
At cranking RPM speeds, the camshaft decompression levers rest against the side of the
exhaust cam lobes, protruding out from the heal of the lobe. This protrusion contacts the
exhaust valve rocker arms during the compression stroke, slightly opening the exhaust
valve.
With the increase of centrifugal force at engine running speeds, the decompression levers
swing out of contact with the exhaust valve rocker arms, allowing the exhaust valves to
operate normally during the compression stroke.

a - Exhaust valve rocker arm

b - Decompression lever

1. Inspect the camshaft for pitting, heat discoloration, or scratches, and for the following
measurements. Replace the camshaft if worn or not within specification.
2. Inspect the compression relief cam lever if equipped, for free movement. Replace the
camshaft if necessary.

a - Compression relief cam

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 Cylinder Head

3. Measure the cam lobe length, and width.

a
b

Cam lobe specifications

Intake 30.83 - 31.03 mm (1.214 - 1.222 in.)
a
Exhaust 30.83 - 31.03 mm (1.214 - 1.222 in.)
Intake 25.90 - 26.10 mm (1.020 - 1.028 in.)
b
Exhaust 25.90 - 26.10 mm (1.020 - 1.028 in.)

4. Measure the camshaft bore diameters, and the camshaft bearing diameters.

Camshaft bore
Inside diameter “a” 37.000 - 37.025 mm (1.4567 - 1.4577 in.)

Camshaft
Diameter “b” 36.935 - 36.955 mm (1.4541 - 1.4549 in.)

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Cylinder Head

Cylinder Head
1. Inspect the cylinder head for the following conditions:
• Mineral deposits/corrosion in water passageways.
• Carbon deposits in combustion chamber. Use round scraper to clean away
deposits. Be careful not to scratch or remove material.
2. Using a straight edge, and a thickness gauge, inspect the cylinder head for warpage.
Replace the cylinder head if not within specification. Measure in the locations illustrated.

56899

Cylinder head warp

Limit 0.1 mm (0.004 in.)

Valve Guide inspection

1. Measure the valve guide bore. If the valve guide wear is not within specification, replace
the valve guide.

58257

Valve guide inside diameter “a”

Intake and exhaust 5.500 - 5.512 mm (0.2165 - 0.2170 in.)

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 Cylinder Head

Valve Guide Replacement

1. Heat the cylinder head in an oven to 200 °C (390 °F). This will help to ease guide removal
and installation, and to maintain correct interference fit.
2. Remove the valve guide using a valve guide remover.

a - Valve guide remover

Valve Guide Remover 91-809495A1

3. Install the new valve guide, and circlip using a valve guide installer bushing along with
the valve guide remover.

a - Valve guide remover

b - Valve guide installer bushing
Valve Guide Remover 91-809495A1
Valve Guide Installer Bushing 91-809496A1

4. After installing the valve guide, ream the valve guide using a valve guide reamer to ob-
tain proper stem-to-guide clearance.

a - Valve guide reamer

Valve Guide Reamer 91-809497A1

90-883064R02 JULY 2006 Page 4A-31

Cylinder Head

Valves
1. Clean the carbon deposits from the valve. Discard any cracked, warped, or burned
valves.
2. Measure the valve stem diameter to check for wear. Replace the valves if not within
specification.

Valve stem diameter “a”

Intake valve 5.475 - 5.490 mm (0.2156 - 0.2161 in.)
Exhaust valve 5.460 - 5.475 mm (0.2150 - 0.2156 in.)

3. Check the valve face for pitting. Valve faces that are pitted must be refaced.
NOTE: Several different types of equipment are available for refacing valves. Follow the
equipment manufacturer’s instructions.
NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat,
and valve face should be lapped.
4. Check the margin thickness of the valves after the valves have been ground. Any valve
with a margin thickness of less than the specification, should be replaced.

45 °

Margin thickness “a”

Intake valve 0.5 - 0.9 mm (0.020 - 0.035 in.)
Exhaust valve 0.5 - 0.9 mm (0.020 - 0.035 in.)

Page 4A-32 90-883064R02 JULY 2006

 Cylinder Head

5. Measure the valve stem runout. Replace if not within specification.

Valve stem runout limit (maximum)

Intake and exhaust 0.016 mm (0.0006 in.)

Valve Springs
1. Check each spring under load on a spring tester. Replace any weak springs.

2. Check the free length limit of each spring. Replace the valve springs if not within
specification.

Valve spring
Free length 37.85 - 39.85 mm (1.491 - 1.569 in.)

90-883064R02 JULY 2006 Page 4A-33

Cylinder Head

3. Check each spring on a flat surface using a square. Rotate the spring, and check the
space between the top coil, and square. Replace the valve springs if not within
specification.

Valve spring
Tilt specification “a” Less than 1.7 mm (0.06 in.)

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 Cylinder Head

Valve Seat Reconditioning

1. Clean the carbon deposits from the combustion chambers, and valve seats, and check
for pitting.
NOTE: Several different types of equipment are available for reseating valve seats. Follow
the equipment manufacturer’s instructions.
2. Measure the valve seat width. Resurface the valve seat if not within specification.
3. Reface the valve seat, use a 60°, 45°, 15° valve seat cutter.
NOTE: When twisting the cutter, keep an even downward pressure to prevent chatter
marks.

Valve seat width specification “a”

Intake and exhaust 0.9 - 1.1 mm (0.035 - 0.043 in.)

NOTE: If resurfacing the valve seats is required, resurface the valve seats to the specified
angles shown in the chart following.

b
a

Valve seat angle specifications

a 15°
b 45°
c 60°

90-883064R02 JULY 2006 Page 4A-35

Cylinder Head

Valve Refacing Steps

Condition: The valve seat is centered on the valve face, but it is too wide.

Valve seat cutter set Desired results

15° cutter
Use To reduce valve seat width
60° cutter

Condition: The valve seat is in the middle of the valve face, but it is too narrow.

Valve seat cutter set Desired results

Use 45° Cutter To achieve a uniform valve seat width

Condition: The valve seat is too narrow, and it is near the valve margin.

Valve seat cutter set Desired results

15° cutter, first
Use To center the seat,
seat and to achieve its width
45° cutter

Page 4A-36 90-883064R02 JULY 2006

 Cylinder Head

Condition: The valve seat is too narrow, and it is located near the bottom edge of the valve
face.

Valve seat cutter set Desired results

60° cutter, first
Use To center the seat,
seat and to increase its width
45° cutter

Cylinder Head Reassembly

Valve Installation
INTAKE AND EXHAUST VALVE COMPONENTS

e
d
c
b
a
a - Valve
b - Valve seal
c - Valve spring
d - Spring retainer
e - Valve keepers

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Cylinder Head

INSTALLING VALVES
NOTE: Always use new valve seals.
1. Apply engine oil to the valves, and valve seats.
2. Compress the valve spring, and retainer, and install the valve keepers around the valve
stem. You may have to tap lightly on the end of the valve to seat the keepers.
NOTE: Valve springs are symmetrical, and may be installed in either direction.

a - Valve spring compressor tool

b - Valve keepers
Valve Spring Compressor Tool 91-809494A1

Tube Ref. Description Mercury Part Number Quicksilver Part

No. Number

110 4-Stroke 10W-30 Outboard Oil 92-802833A1 92-802833Q1

Camshaft Oil Seal Installation

1. If removed, install a new oil seal. Position the seal so the part number side is facing
outward. Press the seal in until it makes contact with the inside flat surface.

58261

a - Upper camshaft oil seal

Page 4A-38 90-883064R02 JULY 2006

 Cylinder Head

Camshaft Installation
1. Apply engine oil to the four main journals on the camshaft.
2. Slide the camshaft into the cylinder head; threaded end towards driven gear.
NOTE: Camshaft retaining pin groove must align with the retaining pin hole in the cylinder
head.
3. Install the camshaft retaining pin. Install the seal over the pin.
4. Place the driven gear on the camshaft so the alignment pin is in the hole. Hold gear with
the tool, and fasten with washer and screw. Tighten screw to the specified torque.
5. Remove any oil from the camshaft lobes, and apply Moly Grease to the lift portion of the
lobes. Obtain Moly Grease from a local source.
NOTE: Rotate camshaft after assembly to ensure it rotates smoothly.
f e

d c

a b
58477

58287

58278
a - Camshaft d - Driven gear
b - Camshaft retaining pin with seal e - Washer
c - Alignment pin f - Screw (M10 x 40)
Tube Ref. Description Mercury Part Number Quicksilver Part
No. Number
110 4-Stroke 10W-30 Outboard Oil 92-802833A1 92-802833Q1
Loctite Moly Paste Obtain Locally Obtain Locally
113 (Molybdenum Disulfide Grease)

Description Nm lb. in. lb. ft.

Driven gear screw 38 28

90-883064R02 JULY 2006 Page 4A-39

Cylinder Head

Oil Pump Installation

1. Refer to Section 4C - Oil Pump Removal.

Rocker Arm Shaft Assembly

1. Apply engine oil to the rocker shaft, and arms.
2. Locate the end of the rocker shaft that is installed towards the driven gear. The oil holes
will align with the mating oil holes in the cylinder head.
3. Slide the rocker arms onto the rocker shaft as shown.
a
b

110

53739

a - Rocker shaft
b - Rocker arm (6)
Tube Ref. Description Mercury Part Number Quicksilver Part
No. Number

110 4-Stroke 10W-30 Outboard Oil 92-802833A1 92-802833Q1

Page 4A-40 90-883064R02 JULY 2006

 Cylinder Head

Rocker Arm Shaft Installation

1. Install the rocker arm shaft assembly as shown.
2. Install the rocker arm retainers on the rocker shaft as shown. Tighten screws to the spe-
cified torque.
NOTE: Leave all adjustment screws loose at this time.

110
c
b

58987

a - Mounting screw (4) (M8 x 30)

b - Rocker arm retainer (1)
c - Rocker arm retainer (2), arrow must point toward driven gear
d - Rocker arm retainer (1)
e - Rocker arm retainer (1)
f - Rocker arm retainer (1), arrow must point toward driven gear
Tube Ref. Description Mercury Part Number Quicksilver Part
No. Number

110 4-Stroke 10W-30 Outboard Oil 92-802833A1 92-802833Q1

Description Nm lb. in. lb. ft.

Rocker arm shaft mounting screw 18 160

90-883064R02 JULY 2006 Page 4A-41

Cylinder Head

Cylinder Head Gasket

1. Install the new cylinder head gasket, and dowel pins.

a - Gasket
b - Dowel pin (2)

Page 4A-42 90-883064R02 JULY 2006

 Cylinder Head

Cylinder Head Installation

1. Apply engine oil to the threads of each screw, and seat surface.
2. Fasten cylinder head with screws shown. Do not tighten.

110

b
a

a - Screw (8) (M9 x 95)

b - Flange screw (4) (M6 x 25)
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard 92-802833A1 92-802833Q1
110 Oil

90-883064R02 JULY 2006 Page 4A-43

Cylinder Head

3. Torque the center screws in sequence, and in two steps.

4. Torque the cylinder head, and intake manifold screws in sequence, and in two steps.
5. Install the timing belt. Refer to Section 4A - Timing Belt Installation.
6. Adjust the valve clearance. Refer to Section 4A - Valve Clearance Adjustment.
7. Install the valve cover. Refer to Section 4A - Valve Cover Installation.

6
7 8

4
4
3

b
4
2 1
2
3

5
1 2
c
1

3
6

5
a

a - Center screw (8) (M9 x 95)

b - Flange screw (4) (M6 x 25)
c - Intake manifold screw (6) (M6 x 25)
Description Nm lb. in. lb. ft.
Intake manifold screw 8 70
Cylinder head center screw (8) First 23 17
Cylinder head center screw (8) Second 47 35
Cylinder head flange screw (4) First 6 53
Cylinder head flange screw (4) Second 12 106

Page 4A-44 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Powerhead
Section 4B - Cylinder Block/Crankcase
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-2 Selecting New Main Bearings . . . . . . . . . . 4B-25
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3 Main Bearing Installation . . . . . . . . . . . . . . 4B-26
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-4 Selecting New Connecting Rod Bearings 4B-27
Cylinder Block And Crankcase . . . . . . . . . . . . 4B-6 Installing Connecting Rod Bearings . . . . . 4B-27
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 4B-8 Connecting Rod Installation . . . . . . . . . . . . 4B-28
Powerhead Removal . . . . . . . . . . . . . . . . . . . . 4B-9 Piston Ring Installation . . . . . . . . . . . . . . . . 4B-29
Removing Powerhead Components . . . . . . . 4B-12 Piston Installation . . . . . . . . . . . . . . . . . . . . 4B-30
Cylinder Block Disassembly . . . . . . . . . . . . . . 4B-13 Crankshaft Installation . . . . . . . . . . . . . . . . 4B-31
Crankcase and Crankshaft Removal . . . . 4B-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-17
Crankcase Cover Installation . . . . . . . . . . .
Thermostat and Exhaust Cover
4B-32 4
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . 4B-17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-34 B
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-18 Drive Gear Installation . . . . . . . . . . . . . . . . 4B-35
Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-19 Installing Powerhead Components . . . . . . 4B-36
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . 4B-19 Engine Wiring Harness and Ignition
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-20 Electrical Component Installation . . . . . . 4B-36
Checking Main Bearing Clearance . . . . . . 4B-21 Ignition Components . . . . . . . . . . . . . . . . . . 4B-36
Checking Connecting Rod Bearing Charging and Starting System
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-23 Components . . . . . . . . . . . . . . . . . . . . . . . . 4B-36
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-24 Fuel Components . . . . . . . . . . . . . . . . . . . . 4B-36
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . 4B-24 Powerhead Installation . . . . . . . . . . . . . . . . . . . 4B-37
Cylinder Block Reassembly . . . . . . . . . . . . . . . 4B-25 Tiller Handle Models . . . . . . . . . . . . . . . . . . 4B-40

90-883064R02 JULY 2006 Page 4B-1

Cylinder Block/Crankcase

Special Tools
1. Oil Filter Wrench (P/N 91-802653Q02)

2. Flywheel Holder (P/N 91-83163M)

3. Flywheel Puller (P/N 91-83164M)

4. Piston Ring Compressor (FT2997)

5. Piston Ring Expander (P/N 91-24697)

Page 4B-2 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Specifications
Type 4-Stroke Cycle - Overhead camshaft
Cylinder
Displacement 747 cc (45.6 cu. in.)
Block
Number of Cylinders 3
Stroke Length 75 mm (2.953 in.)
Diameter
Standard 65 mm (2.5591 in.)
Cylinder Oversize - 0.25 mm (0.010 in.) 65.25 mm (2.5689 in.)
Bore Oversize - 0.50 mm (0.020 in.) 65.5 mm (2.5787 in.)
Taper/Out of Round Maximum 0.08 mm (0.003 in.)
Bore Type Cast iron
Piston Type Aluminum
O.D. at Skirt
Piston Standard 64.950 - 64.965 mm (2.5570 - 2.5578 in.)
Oversize - 0.25 mm (0.010 in.) 65.2 - 65.215 mm (2.5669 - 2.5675 in.)
Oversize - 0.50 mm (0.020 in.) 65.450 - 65.465 mm (2.5768 - 2.5774 in.)
Piston Piston to Cylinder Clearance 0.035 - 0.065 mm (0.0014 - .0026 in.)
Clearance
Ring End Gap (Installed)
Top 0.15 - 0.03 mm (0.006 - 0.012 in.)
Middle 0.30 - 0.50 mm (0.012 - 0.020 in.)
Rings Bottom (Oil Ring) 0.20 - 0.70 mm (0.008 - 0.028 in.)
Side Clearance:
Top 0.02 - 0.06 mm (0.0008 - 0.0024 in.)
Middle 0.02 - 0.06 mm (0.0008 - 0.0024 in.)
Compression Ratio 9.7:1
Compresion
Cylinder Compression 1241 - 1448 kPa (180 - 210 psi)
Ratio
(Electric Models Only, Cold Engine @ WOT)
Piston Pin Piston Pin Diameter 15.965 - 15.970 mm (0.6285 - 0.6287 in.)
Connecting Oil Clearance (Big End) 0.020 - 0.052 mm (0.0008 - 0.0020 in.)
Rods Small End Inside Diameter 15.985 - 15.998 mm (0.6293 - 0.6298 in.)
Main Bearing Clearance 0.012 - 0.044 mm (0.0005 - 0.0017 in.)
Crankshaft
Crankshaft Runout 0.046 mm (0.0018 in.)

90-883064R02 JULY 2006 Page 4B-3

Cylinder Block/Crankcase

Crankshaft
110

12

2
8
9
10

110 7
110 6
11
1 110
12

5 110
4

110

110

Page 4B-4 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Crankshaft
Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
1 1 Crankshaft
2 1 Oil seal
3 1 Oil seal
4 4 Connecting rod
5 6 Bolt 17 150
6 Bearing (Brown)
6 6 Bearing (Black)
6 Bearing (Blue)
7 3 Piston
8 3 Piston ring (Top)
9 3 Piston ring (Second)
10 3 Piston oil ring
11 3 Piston pin
12 6 Retainer

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

90-883064R02 JULY 2006 Page 4B-5

Cylinder Block/Crankcase

Cylinder Block And Crankcase

Page 4B-6 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Cylinder Block And Crankcase

Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
1 1 Cylinder block
2 2 Dowel pin
3 3 Plug 9 79
4 1 Pipe plug (1/2-14) 33 24
5 1 Pipe plug (3/4-14) 33 24
8 Bearing (Brown)
6 8 Bearing (Black)
8 Bearing (Blue)
7 1 Nipple 40 29.5
8 8 Screw (M8 x 82) 30 22
9 8 Screw (M6 x 35) 12 102
10 1 Gasket
11 1 Oil filter 8 70
12 1 Gasket
13 1 Exhaust cover
14 1 Pipe plug Drive Tight
15 1 Thermostat
16 1 Gasket
17 1 Cover
18 10 Screw (M6 x 35) 12 106
19 1 Elbow Drive Tight
20 3 Cable tie
21 1 Tubing (10 in.)
22 1 Engine coolant temperature (ECT) sensor 1.5 15
23 1 O-ring
24 1 Lifting eye
25 1 Screw (M8 x 35) 39.5 29
26 1 Hose (19 in.)

A = To VST cooler
B = To fitting in adapter plate

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

12 Loctite Master Gasket Kit 92-12564-2 92-12564-2

Loctite 567 PST Pipe

9 92-809822 92-809822
Sealant

90-883064R02 JULY 2006 Page 4B-7

Cylinder Block/Crankcase

Torque Sequence
Exhaust Cover Crankcase Cover
9

10
7
13 5 6 14
4

3 9 10
1 2
1
12 11
2 4 3

16 15
5
6 8 7
8

Intake Manifold Powerhead

4
5 6
3

1 2
1
2
3 4

7 8

Page 4B-8 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Powerhead Removal
WARNING
The possibility exists that the engine could start when turning the flywheel. To avoid
possible serious injury, always disconnect the battery, and remove spark plug
leads from spark plugs before working on motor.
1. On electric start models, disconnect the battery cables from the battery. Remove battery
cables from engine.
2. Disconnect the power trim wires if equipped.
3. Remove the bottom cowls.

a
b

a - Screw (6) (M6 x 30)

b - Lower cowl
c - Screw (M6 x 60)

4. Drain the engine oil.

5. Remove the control cable anchor bracket screws on remote control models.
6. Remove the throttle/shift lever screw, and swing the entire shift linkage to the side.

58810
a

Remote Control Model (Bigfoot)

a - Control cable anchor bracket screw (2) (M6 x 16)
b - Throttle/shift lever
c - Shift lever screw (1) (M8 x 70)

90-883064R02 JULY 2006 Page 4B-9

Cylinder Block/Crankcase

7. Push the retainer up, and slide over to disengage the vertical shift shaft.

Remote Control Model (Non Bigfoot)

a - Retainer

8. Remove the shift guide bracket screws.

Tiller Handle Model

58479

Tiller Handle Model

a - Shift guide bracket
b - Screw (2) (M6 x 25)

Page 4B-10 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

9. Disconnect the crankcase vent hose.

10. Disconnect the fuel supply hose from the water separating fuel filter.

58974

a - Crankcase vent hose

b - Fuel supply hose to water separating fuel filter

11. Disconnect the power trim wires from the trim motor.

90-883064R02 JULY 2006 Page 4B-11

Cylinder Block/Crankcase

12. Remove the powerhead mounting bolts.

13. Lift the powerhead from the driveshaft housing.

58979

a
a - Powerhead mounting bolts (4 each side) (M8 x 45)
b - Hoist

Removing Powerhead Components

1. Place the powerhead on the bench.
2. Remove the intake assembly. Refer to Section 3C - Intake Assembly Removal.
3. Remove the vapor separator assembly. Refer to Section 3C - Vapor Separator
Removal.
4. Remove the flywheel, stator, and starter. Refer to Section 2B - Charging & Starting
System.
5. Disconnect/remove components in the following order: three ECM bracket screws, main
harness ground wire screws near bottom of starter, starter solenoid mounting screws,
oil pressure switch, ECT sensor, regulator/rectifier mounting screws, crank position
sensor mounting screws, and ignition coil mounting screws.
6. Remove the electrical components as an assembly. Disconnect the wiring, and cut cable
ties as necessary.
7. Remove the cylinder head. Refer to Section 4A - Cylinder Head Removal.

Page 4B-12 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Cylinder Block Disassembly

1. Remove the drive gear components.

a - Load ring
b - Drive gear
c - Woodruff key

2. Remove the exhaust cover, and gasket.

3. Remove the oil filter.

f
e
c
d h
b

a - Screw and washer (10) (M6 x 35)

b - Thermostat cover
c - Gasket (discard)
d - Thermostat
e - Exhaust cover
f - Gasket
g - Oil filter
h - Oil filter wrench
Oil Filter Wrench 91-802653Q02

90-883064R02 JULY 2006 Page 4B-13

Cylinder Block/Crankcase

Crankcase and Crankshaft Removal

1. Remove crankcase cover, and dowel pins.

c d

56875

b
a
a - Screw and washer (8) (M8 x 82)
b - Screw and washer (8) (M6 x 35)
c - Crankcase cover
d - Dowel pin (2)

2. With a rubber or plastic hammer, lightly strike the crankcase cover in order to separate
it from the block. If the cover will not separate, try prying it off with a screwdriver. Do not
damage the split line sealing surface when prying the cover off.

Page 4B-14 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

3. Use a 5/16 in., 12 point socket, and remove connecting rod bolts and caps.
NOTE: Each connecting rod and cap are a matched set.
4. Remove carbon ridge from the cylinder bore using a burr knife. Push out the connecting
rod/piston assembly. Keep each piston, connecting rod, and cap together as an assembly.

c
56876

a - Connecting rod screw (6)

b - Connecting rod cap (3)
c - Connecting rod/piston assembly (3)
NOTE: Use an indelible marker to scribe the cylinder number on each piston and connecting
rod so they can be reinstalled in their original location.
5. Disassemble piston/connecting rod assembly. Remove circlip with a needle nose pliers.
6. Remove piston rings. Use a piston ring expander tool to prevent rings from breaking
during removal.

d c

f
e

a 53824
b
a - Circlip
b - Connecting rod and cap
c - Scribe the cylinder number here
d - Connecting rod bearings
e - Piston rings
f - Piston ring expander
Piston Ring Expander 91-24697

90-883064R02 JULY 2006 Page 4B-15

Cylinder Block/Crankcase

7. Remove the crankshaft from the block.

56877
c
a - Crankshaft
b - Upper oil seal
c - Lower oil seal

NOTE: Do not interchange main bearings, reinstall in their original locations.

8. Remove main bearing halves from the crankcase cover, and cylinder block.

56878
b
a - Main bearing halves - Crankcase cover (4)
b - Main bearing halves - Cylinder block (4)

Page 4B-16 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Inspection
Cylinder Bore
MEASURING CYLINDER BORE
1. Measure the cylinder bore diameter at three locations in both X and Y axis.
2. If the cylinder bore is beyond the standard limits listed in the tables below, it will be
necessary to rebore the cylinder to accept the oversize piston.
NOTE: Measure at three locations (L1 , L2 , and L3 ) in both X and Y axis (D1-6 ).
L1 = 20 mm (0.8 in.)
L2 = 40 mm (1.6 in.)
L3 = 60 mm (2.4 in.)
1. Inspect:
a. Water jacket for mineral deposits/corrosion, clean if necessary.
b. Inner surface for score marks, repair if necessary.
2. Measure bore diameter with a cylinder gauge, rebore or replace if necessary.

L1
D1,2
L2
L3
D3,4

D5,6

55837

Cylinder bore
Maximum taper 0.08 mm (0.003 in.)
Maximum out of round 0.08 mm (0.003 in.)
Standard bore finish hone 65 mm (2.5591 in.)
Oversize bore finish hone - 0.25 mm (0.010 in.) 65.25 mm (2.5689 in.)
Oversize bore finish hone - 0.50 mm (0.020 in.) 65.5 mm (2.5787 in.)

NOTE: Taper = (Maximum of D1 or D2 ) - (Minimum of D5 or D6 ).

90-883064R02 JULY 2006 Page 4B-17

Cylinder Block/Crankcase

Piston
1. Inspect the piston wall wear/damage. Replace if necessary.

2. Measure the piston at a point 5.0 mm (0.2 in.) from the bottom. Replace if out of
specification.

a
b

a - Piston diameter
b - 5.0 mm (0.2 in.)
Piston diameter “a”
Standard 64.950 - 64.965 mm (2.5570 - 2.5578 in.)
Oversize- 0.25 mm (0.010 in.) 65.2 - 65.215 mm (2.5669 - 2.5675 in.)
Oversize - 0.50 mm (0.020 in.) 65.450 - 65.465 mm (2.5768 - 2.5774 in.)

3. Measure piston to cylinder clearance. If out of specification examine piston and cylinder
bore further to determine repair/replacement.
a. Piston to cylinder wall clearance can be defined by:

Minimum bore measurement - maximum piston measurement = piston to

cylinder wall clearance.

Piston
Piston to cylinder clearance 0.035 - 0.065 mm (0.0014 - 0.0026 in.)

Page 4B-18 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Piston Pin
1. Measure the piston pin diameter. Replace the piston pin if out of specification.

55839

Piston
Piston pin diameter 15.965 - 15.970 mm (0.6285 - 0.6287 in.)

2. Place the piston pin into the connecting rod, and check for free play. There should be
no noticeable free play.

55840

3. Place the piston pin into the piston, and check for free play. There should be no
noticeable free play.

55841

Piston Rings
Piston Ring Side Clearance
1. Measure the piston ring side clearance. Replace the piston and/or piston rings if out of
specification.

55842

Piston ring side clearance

Top 0.02 - 0.06 mm (0.0008 - 0.0024 in.)
Middle 0.02 - 0.06 mm (0.0008 - 0.0024 in.)

90-883064R02 JULY 2006 Page 4B-19

Cylinder Block/Crankcase

Piston Ring End Gap Clearance

1. Insert the piston ring into the cylinder bore.
2. Push the piston ring into the cylinder bore with the piston to an approximate depth of 20 mm
(0.8 in.).
3. Measure the piston ring end gap clearance. Replace the piston ring if out of
specification.

53747

a - Piston ring depth of 20 mm (0.8 in.)

Piston ring end gap
Top 0.15 - 0.30 mm (0.006 - 0.012 in.)
Second 0.30 - 0.50 mm (0.012 - 0.020 in.)
Oil control 0.20 - 0.70 mm (0.008 - 0.028 in.)

Crankshaft
1. Thoroughly clean the crankshaft, and inspect the bearing surfaces. Replace the
crankshaft if the bearing surfaces are pitted, scored, or discolored.
2. Measure the runout. Replace the crankshaft if out of specification.
3. Clean the oil holes in the crankshaft.

Crankshaft
Runout 0.046 mm (0.0018 in.)

Page 4B-20 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Checking Main Bearing Clearance

IMPORTANT: Do not interchange the main bearings. Reinstall in their original
position.
1. Clean all the old sealing material from the split line on the crankcase cover, and cylinder
block.
2. Clean all the oil from the following areas:
• Main bearing surfaces on the cylinder block, and crankcase cover.
• Main bearings.
• Crankshaft bearing surfaces.
NOTE: For selecting, and installing main bearings, refer to Section 4B - Cylinder Block
Reassembly.
3. Install the main bearings.
4. Place the crankshaft into the cylinder block.

53811

5. Place a piece of plastigauge onto each crankshaft bearing surface.

53812

a - Plastigauge

NOTE: Do not install plastigauge over the oil hole on the bearing surface of the crankshaft.

90-883064R02 JULY 2006 Page 4B-21

Cylinder Block/Crankcase

6. Install the crankcase cover. Apply oil to the cover bolts, and torque cover bolts in
sequence, and in two steps.

13 5 6 14

9 10
1 2

12 11
4 3

16 15

8 7

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

Description Nm lb. in. lb. ft.

Center bolts (8) (M8 x 82) First 15 11
Center bolts (8) (M8 x 82) Second 30 22
Outer bolts (8) (M6 x 35) First 6 53
Outer bolts (8) (M6 x 35) Second 12 106

7. Remove the crankcase cover. Measure the compressed plastigauge to check the main
bearing oil clearance. Replace the bearings if the clearance is not in specification.

53751

Crankshaft
Main bearing oil clearance 0.012 - 0.044 mm (0.0005 - 0.0017 in.)

NOTE: For selecting, and installing main bearings, refer to Section 4B - Selecting New
Main Bearings.

Page 4B-22 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Checking Connecting Rod Bearing Clearance

IMPORTANT: Do not interchange used connecting rod bearings. Reinstall bearings
in their original position.
1. Clean all the oil from the connecting rod bearing surfaces, and connecting rod journals
on the crankshaft.
NOTE: For selecting, and installing connecting rod bearings, refer to Section 4B -
Selecting New Connecting Rod Bearings.
2. Place a piece of plastigauge on the connecting rod journals.

a
53751

a - Plastigauge

IMPORTANT: Do not rotate the connecting rod when checking the clearance.
3. Install the connecting rod to the respective journal. Tighten connecting rod bolts in
sequence, and in two steps to the specified torque.

a c
b

a - Connecting rod cap

b - Scribe marks on cap and rod
c - Connecting rod bolts
Description Nm lb. in. lb. ft.
Connecting rod bolt First 6 53
Connecting rod bolt Second 17 150

90-883064R02 JULY 2006 Page 4B-23

Cylinder Block/Crankcase

4. Remove the connecting rod cap. Measure the compressed plastigauge to check the
connecting rod oil clearance. Replace the bearings if oil clearance is not in specification.

53810

Connecting rod
Oil clearance 0.020 - 0.052 mm (0.0008 - 0.0020 in.)

Thermostat
1. Measure the lift of the thermostat at the operating water temperature listed.

Water temperature Valve lift

48° - 51 °C (118 - 123 °F) Starts to open
Above 63 °C (145 °F) Minimum 3 mm (0.12 in.)

Oil Pressure Switch

1. Check the continuity of the switch.

55845

Oil switch continuity check

Below 20.0 kPa (2.9 psi) Continuity
Above 20.0 kPa (2.9 psi) No continuity

Page 4B-24 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Cylinder Block Reassembly

Selecting New Main Bearings
1. Locate the main bearing code letters on the cylinder block.
2. Refer to the following reference chart to select the correct main bearings.
3. Use the color coded main bearings that match the main bearing code letter.
Main bearing code letter Main bearing color code
A Blue
B Black
C Brown

b a

A B C
#1

#2
#3
#4

a - Main bearing code letters

b - Main bearing identification color location

90-883064R02 JULY 2006 Page 4B-25

Cylinder Block/Crankcase

Main Bearing Installation

IMPORTANT: Do not interchange used main bearings. Reinstall in their original
position.
1. Check clearance of each bearing. Refer to Section 4B - Checking Main Bearing
Clearance.
2. Clean all the oil from the main bearing surfaces on the cylinder block, and crankcase
cover.
3. Install main bearings. Make sure the locking tab on each bearing fits into its notch in the
cylinder block.

a
110

d
c

a - Main bearing halves - Crankcase cover (4)

b - Main bearing halves - Cylinder block (4)
c - Projection in bearing
d - Notch in cylinder body/crankcase
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

Page 4B-26 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Selecting New Connecting Rod Bearings

1. Locate the connecting rod bearing code letter that is scribed on the side of the
connecting rod.
2. Refer to the following reference chart to select the correct connecting rod bearings.
3. Use the color coded connecting rod bearings that match the connecting rod bearing
code letter.
Connecting rod bearing code letter Connecting rod bearing color code
A Blue
B Black
C Brown

A
B
C
53816

a - Connecting rod bearing code letters

b - Connecting rod bearing identification color location

Installing Connecting Rod Bearings

IMPORTANT: Do not interchange used connecting rod bearings. Reinstall bearings
in their original position.
1. Clean all the oil from the bearing surfaces on the connecting rod.
2. Install the connecting rod bearings. Ensure the locking lug on each bearing fits into its notch.

b 53815

a - Connecting rod bearings

b - Fit the locking lugs into the notches

90-883064R02 JULY 2006 Page 4B-27

Cylinder Block/Crankcase

Connecting Rod Installation

1. Lubricate the piston pin with oil, and assemble the piston to the connecting rod. Always
use new circlips.
IMPORTANT: Install the split end of the circlip into the groove first, push the other end
down until it snaps into the groove. If the shape of the circlip is permanently distorted
when attempting installation, discard it, and use a new one.
IMPORTANT: Install the side of the connecting rod marked with a “Y” towards “UP”
on the piston face.
IMPORTANT: The piston pin clip should be installed with the end gap facing opposite
of pry point.
b e

110
c

d
a - Connecting rod
b - Piston
c - Piston pin
d - Piston pin clip (2)
e - Piston pin clip end gap
f - Pry point
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

Page 4B-28 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Piston Ring Installation

IMPORTANT: Use caution when installing piston rings to avoid scratching piston.
1. Install the oil ring components as shown. Spread the rings to slip over the piston.
2. Install the second, and top compression rings “T” side up. Spread the rings to slip over
the piston.
3. Offset the piston ring end gaps.

110

e
110
f

c
a
b d

50°
g
UP
h

i
j

k
a - Oil ring spacer
b - Bottom rail
c - Top rail
d - Second compression ring - “T” side up
e - Top compression ring - “T” side up
f - “T” mark should face piston crown
g - End gap - Top compression ring
h - End gap - Second compression ring
i - End gap - Upper oil ring rail
j - End gap - Lower oil ring rail
k - End gap - Oil ring spacer
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

90-883064R02 JULY 2006 Page 4B-29

Cylinder Block/Crankcase

Piston Installation
NOTE: Cylinder bores must be clean before installing the pistons. Clean with light honing, as
necessary. After honing, clean cylinder bores with water, and detergent. After cleaning, swab
cylinder bores several times with engine oil, and a clean cloth, then wipe with a clean dry cloth.
1. Lubricate the pistons, rings, and cylinder walls with engine oil.
2. Install the piston/connecting rod assembly using the piston ring compressor tool.
NOTE: Install used pistons in their original locations. Install the piston with “UP” mark on the
piston crown facing toward the flywheel end of the block.

ÎÎÎ
ÎÎÎ
ÎÎÎ
a

a - Piston ring compressor

b - Flywheel end
Piston ring compressor FT2997

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

Page 4B-30 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Crankshaft Installation
1. Lubricate the crankshaft bearing surfaces, connecting rod journals, and oil seal lips with
the engine oil.

110

110

a - Upper oil seal

b - Lower oil seal
c - Crankshaft bearing surface
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

2. Install upper, and lower oil seals on crankshaft. Position the oil seal lips as shown.
3. Carefully lower the crankshaft into place.
IMPORTANT: Make sure the lower oil seal notch is positioned into the groove in the
crankcase.

b
58273

a - Upper oil seal

b - Lower oil seal - Raised rib
c - Oil seal groove

90-883064R02 JULY 2006 Page 4B-31

Cylinder Block/Crankcase

4. Assemble the connecting rods to the crankshaft. Install the connecting rod caps, aligning
the code letter scribed on the connecting rod and cap.
5. Apply oil to the connecting rod bolts. Tighten bolts in two steps to the specified torque.

a
c
b
110

a - Connecting rod cap (3)

b - Connecting rod bolt (6)
c - Scribe code letter
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

Description Nm lb. in. lb. ft.

Connecting rod bolt First 6 53
Connecting rod bolt Second 17 150

Crankcase Cover Installation

1. Clean off all oil from the contacting surfaces of the crankcase cover, and cylinder block.
IMPORTANT: Make sure the contacting surface of the crankcase cover, and cylinder
block are clean before applying gasket sealant.
2. Apply a smooth even coat of Loctite Master Gasket Sealant to the contacting surfaces
on the crankcase cover. Use a small paint roller to spread out the sealant for a smooth
even coverage.
NOTE: Do not apply gasket sealant to the main bearings or the bolt holes.

a 12
b

a - Loctite Master Gasket sealant

b - Paint roller
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

12 Loctite Master Gasket Kit 92-12564-2 92-12564-2

Page 4B-32 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

3. Install the crankcase cover on the cylinder block. Dowel pins will align the two mating
surfaces.
4. Apply oil to the screw threads. Torque the screws in the sequence shown below. Tighten
to the first torque value specified below. Repeat this torque sequence for the second
torque value.

a
13 5 6 14

9 10
1 2

12 11
110 4 3

16 15
a
8 7
a - Dowel pin (2)
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil

Description Nm lb. in. lb. ft.

Crankcase cover center screws (8) (M8 x 82) First 15 11
Crankcase cover center screws (8) (M8 x 82) Second 30 22
Crankcase cover outer screws (8) (M6 x 35) First 6 53
Crankcase cover outer screws (8) (M6 x 35) Second 12 106

90-883064R02 JULY 2006 Page 4B-33

Cylinder Block/Crankcase

Thermostat and Exhaust Cover Installation

1. Install the oil filter. Tighten to the specified torque using the oil filter wrench.
2. Install the exhaust cover along with the thermostat, and thermostat cover. Use new
gaskets.
3. Tighten the screws to the first torque value in the sequence shown below. Repeat this
procedure for the second torque value.

9
b
a
10
d
7 c
e
4

2
h
5
f
6 g
8

a - Exhaust cover
b - Gasket
c - Thermostat
d - Gasket
e - Thermostat cover
f - Oil filter
g - Oil filter wrench
h - Exhaust cover screw (10) (M6 x 35)
Oil Filter Wrench 91-802653Q02

Description Nm lb. in. lb. ft.

Exhaust, and thermostat cover screw First 6 53
Exhaust, and thermostat cover screw Second 12 106
Oil filter 8 70

Page 4B-34 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Drive Gear Installation

1. Install the drive gear components.
NOTE: Load ring can only be used once, and must be replaced if the flywheel is removed.
a

a - Load ring
b - Drive gear
c - Drive key

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Cylinder Block/Crankcase

Installing Powerhead Components

1. Reinstall the cylinder head. Refer to Section 4A - Cylinder Head Installation.

Engine Wiring Harness and Ignition/Electrical Component Installation

1. Install the wiring harness assembly to the powerhead in the same order removed. Refer
to the appropriate section for each components torque value.
Ignition Components
1. Refer to the appropriate section of the service manual for installation, and torque values
of the following ignition components.
a. Timing Belt, Section 4A
b. Ignition Coils, Section 2A
c. ECM, Section 3C
d. Crank Position Sensor, Section 3C
Charging and Starting System Components
1. Refer to Section 2B for installation, and torque values of the following components:
a. Starter Motor
b. Voltage Regulator
c. Stator
d. Flywheel
Fuel Components
1. Refer to Section 3C for intake assembly/vapor separator installation.

Page 4B-36 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

Powerhead Installation
CAUTION
When lubricating the driveshaft splines do not allow any grease on top of the
driveshaft. Grease on top of the driveshaft will force the shaft down when installing
the gearcase, causing the pinion gear to bind with the forward gear. This can result
in damage or failure of the gears.
1. Install the powerhead, and new base gasket.
2. Tighten the powerhead mounting bolts to the first torque value in the sequence shown
below. Repeat this procedure for the second torque value.
IMPORTANT: If the crankshaft splines do not line up with the driveshaft splines, shift
the gearcase into forward, place a prop on the propshaft, and rotate it
counterclockwise. This will allow the splines to line up.

b
5 6

1 2

3 4

7 8

a
a - Powerhead mounting bolts (4 each side) (M8 x 110)
b - Hoist
c - Base gasket
Description Nm lb. in. lb. ft.
Powerhead mounting bolt First 27.1 20
Powerhead mounting bolt Second + 90° turn

90-883064R02 JULY 2006 Page 4B-37

Cylinder Block/Crankcase

3. Reconnect throttle/shift linkage, and control cable anchor bracket. Torque fasteners to
the specified torque.

58810
a

Remote Control Model (Bigfoot)

a - Control cable anchor bracket screw (2) (M6 x 16)
b - Throttle/shift lever
c - Throttle/shift lever screw (1) (M8 x 70)
Description Nm lb. in. lb. ft.
Throttle/shift lever mounting screw 11 100
Cable anchor bracket mounting screw 8.5 75

4. Install the shift guide bracket screws. Tighten to the specified torque.

58479

Tiller Handle Model (Bigfoot)

a - Shift guide bracket
b - Screw (2) (M6 x 25)
Description Nm lb. in. lb. ft.
Shift guide bracket mounting screw 8 70

Page 4B-38 90-883064R02 JULY 2006

 Cylinder Block/Crankcase

5. Push the retainer up, and slide over to engage the vertical shift shaft.

Non Bigfoot Model

a - Retainer

6. Reconnect the hoses. Use cable ties to fasten all hose connections.

d
b

c
e

a - Crankcase vent hose

b - Crankcase breather hose
c - Fuel in hose
d - Fuel out hose
e - Fuel supply hose to water separating fuel filter

90-883064R02 JULY 2006 Page 4B-39

Cylinder Block/Crankcase

7. Reconnect the power trim harness wires.

8. Install the spark plugs
9. Install the bottom cowl. Tighten the screws to the specified torque.

a
b

a - Screw (6) (M6 x 30)

b - Lower cowl
c - Screw (M6 x 60)
Description Nm lb. in. lb. ft.
Bottom cowl screw 7 60

10. Connect the battery cables to the battery terminals.

11. Check the engine oil level.
Tiller Handle Models
1. Install the throttle cables, shift rod, and tiller handle wiring. Refer to Section 7B.

Page 4B-40 90-883064R02 JULY 2006

 Lubrication

Powerhead
Section 4C - Lubrication
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-2 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C-7
Camshaft/Oil Pump . . . . . . . . . . . . . . . . . . . . . . 4C-4 Oil Pump Reassembly . . . . . . . . . . . . . . . . . . . 4C-8
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . 4C-6 Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . 4C-9
Oil Pump Disassembly . . . . . . . . . . . . . . . . . . . 4C-6 Oil Pressure Measurement . . . . . . . . . . . . . . . 4C-10
Cleaning and Inspection . . . . . . . . . . . . . . . . . . 4C-7

4
C

90-883064R02 JULY 2006 Page 4C-1

Lubrication

Specifications
Pump Type Trochoid
Engine Oil Pressure (Warm Engine)
@ 3000 RPM 207 - 278 kPa (30 - 40 psi)
Engine Oil Pan Capacity Either 3 liters or 3 quarts
Oil Pump:
Outer Rotor to Housing “a” 0.11 - 0.23 mm (0.0045 - 0.009 in.)
Inner Rotor to Outer Rotor “b” 0.12 mm (0.005 in.)
Rotor to Housing “c” 0.04 - 0.08 mm (0.0015 - 0.003 in.)

Lubrication a
System bb

cc

Page 4C-2 90-883064R02 JULY 2006

 Lubrication

Notes:

90-883064R02 JULY 2006 Page 4C-3

Lubrication

Camshaft/Oil Pump

Page 4C-4 90-883064R02 JULY 2006

 Lubrication

Camshaft/Oil Pump
Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
1 1 Camshaft
2 1 Pin
3 1 Dowel pin
4 1 Oil pump assembly
5 1 O-ring
6 1 O-ring
7 1 O-ring
8 1 O-ring
9 2 Screw (M6 x 16) 8 70
10 4 Screw (M6 x 40) 8 70

90-883064R02 JULY 2006 Page 4C-5

Lubrication

Oil Pump Removal

IMPORTANT: Do not twist/turn the oil pump from side to side while removing it from
the cylinder head, as the oil pump sealing O-rings will be cut. Pull oil pump away from
the cylinder head by inserting a screwdriver in the pry points on the oil pump body.
1. Remove the cylinder head. Refer to Section 4A - Cylinder Head Removal.
2. Remove the oil pump mounting screws. Separate the oil pump from the cylinder head.

a - Mounting screw (4) (M6 x 40)

Oil Pump Disassembly

1. Use a heat lamp to assist in removing the oil pump screws. Remove the screws.

a - Screw (2)

Page 4C-6 90-883064R02 JULY 2006

 Lubrication

2. Disassemble the oil pump.

c a
a - Cover seal
b - Outer rotor
c - Inner rotor
d - Shaft
e - Cross pin

Cleaning and Inspection

Oil Pump
1. Check the oil pump components for pitting, and scratches. Replace the oil pump if pitting
and scratches are significant.
2. Use a feeler gauge to measure the following oil pump clearances:
a. Between the outer rotor, and pump housing.
b. Between the inner rotor, and outer rotor.
c. Between the outer rotor, and pump housing.

b
c

55803

Oil pump clearance

a 0.11 - 0.23 mm (0.0045 - 0.009 in.)
b 0.12 mm (0.005 in.)
c 0.03 - 0.08 mm (0.0015 - 0.003 in.)

90-883064R02 JULY 2006 Page 4C-7

Lubrication

Oil Pump Reassembly

1. Reassemble the oil pump assembly.
2. Lubricate the outer and inner rotors thoroughly with the engine oil.

c a
a - Cover seal
b - Outer rotor
c - Inner rotor
d - Shaft
e - Cross pin
Tube Ref. Quicksilver Part
Description Mercury Part Number
No. Number

110 4-Stroke 10W-30 Outboard Oil 92-802833A1 92-802833Q1

3. Fasten cover with two screws. Apply Loctite 222 to the threads. Tighten the screws to
the specified torque.

a 51

a - Screw (2) (M6 x 16)

Tube Ref. Quicksilver Part
Description Mercury Part Number
No. Number

51 Loctite 222 92-809818 92-809818

Description Nm lb. in. lb. ft.

Oil pump cover screw 8 70

Page 4C-8 90-883064R02 JULY 2006

 Lubrication

Oil Pump Installation

1. Place the O-ring seals on the oil pump. Lubricate the O-rings with oil.
2. Prime the oil pump by pouring approximately 30 ml (1 fl. oz.) of engine oil into the oil
pump body.

a a

58260

a - O-ring seals
b - 30 ml of engine oil
Tube Ref. Quicksilver Part
Description Mercury Part Number
No. Number

110 4-Stroke 10W-30 Outboard Oil 92-802833A1 92-802833Q1

IMPORTANT: When the oil pump mounting surface gets close to the mating surface
of the cylinder head, do not twist/turn the oil pump from side to side. The sharp edges
on the cylinder head will cut the oil pump sealing O-rings.
3. Align the oil pump shaft with the camshaft and install the oil pump.
4. Fasten with four screws. Tighten the screws to the specified torque.

c
b
a
e
a - Oil pump assembly
b - Align slot with camshaft projection
c - Screw (4) (M6 x 40)
d - Oil pump mounting surface
e - Cylinder head/oil pump mating surface
Description Nm lb. in. lb. ft.
Oil pump mounting screw 8 70

90-883064R02 JULY 2006 Page 4C-9

Lubrication

Oil Pressure Measurement

1. Warm the engine to the operating temperature. Stop the engine.
2. Remove the oil pressure switch.
3. Install pressure gauge with a range of 0 - 1000 kPa (0 - 150 psi).
NOTE: Pressure gauge port thread size is 1/8 in. NPTF.
a

a - Pressure switch

4. Measure the oil pressure at idle.

5. If out of specification, check oil pump, oil pressure, oil suction pipe, and oil strainer.
6. If above components are within specification and clean, replace oil pressure relief valve.
Refer to Section 5A - Clamp/Swivel Brackets and Driveshaft Housing.

Oil pressure relief specification

At 725 RPM 207 - 278 kPa (30 - 40 psi)

Page 4C-10 90-883064R02 JULY 2006

 Clamp/Swivel Brackets and Driveshaft Housing

Mid-Section
Section 5A - Clamp/Swivel Brackets and Driveshaft Housing
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-2 Adapter Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-9
Transom Bracket . . . . . . . . . . . . . . . . . . . . . . . . 5A-3 Steering Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-11
Swivel Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-5 Bottom Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-13
Driveshaft Housing . . . . . . . . . . . . . . . . . . . . . . 5A-7

5
A

90-883064R02 JULY 2006 Page 5A-1

Clamp/Swivel Brackets and Driveshaft Housing

Specifications
Transom Height:
Long Shaft 51 cm (20 in.)
Steering Pivot Range:
Tiller 90°
Mid-Section
Remote 60°
Tilt Pin Positions 5 + Shallow water
Full Tilt Up Angle 69°
Allowable Transom Thickness 69.8 mm (2-3/4 in.)

Page 5A-2 90-883064R02 JULY 2006

 Clamp/Swivel Brackets and Driveshaft Housing

Notes:

90-883064R02 JULY 2006 Page 5A-3

Clamp/Swivel Brackets and Driveshaft Housing

Transom Bracket

21
45 20
19 22
49
95

44
50 34
48
54 46 23
47
4
14
15
23

38 5 18
39 28 95
40
29
95
33 51
34 24
30 1

36 32 25
53 27
52 41
26
37
35 31 42

43

Page 5A-4 90-883064R02 JULY 2006

 Clamp/Swivel Brackets and Driveshaft Housing

Transom Bracket
Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
13 1 Transom bracket (Port)
14 1 Grease fitting
15 1 Groove pin
16 1 Transom bracket (Starboard)
17 1 Tilt lock lever
18 1 Spring
19 1 Nyliner
20 1 Spring
21 1 Knob
22 1 Groove pin
23 2 Washer
24 1 Anchor bracket
25 1 Anode assembly
26 2 Screw (M6 x 25) 7 60
27 2 Washer
5 Screw (30 mm)
28
1 Screw (35 mm)
29 4 Lockwasher
30 2 Nut
31 1 Tilt pin assembly Non Power Trim
32 1 Spring
33 1 Tilt tube
Tighten nut to 43 Nm
34 2 Nut (32 lb. ft.) and then
back off 1/4 turn
35 1 Seal kit
36 1 O-ring Non handle
37 1 Spacer
38 2 Clip
39 1 C-washer Power Trim
40 1 Screw Drive tight
41 4 Screw Drive tight
42 4 Washer Drive tight
43 4 Nut
44 1 Link
45 1 Tilt lever
46 1 Bushing Non Power Trim
47 1 Washer
48 1 Wave washer
49 1 Tilt knob
50 1 Screw (0.375-16 x 0.62) 25 18
51 2 Screw (M10 x 40)
52 2 Washer
53 2 Nut
54 1 Decal - Tilt lock

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

90-883064R02 JULY 2006 Page 5A-5

Clamp/Swivel Brackets and Driveshaft Housing

Swivel Bracket
1

95 4
5

95 3
7

2
6

16
15

10
11

12
8

95
13
10 10

14

95

Page 5A-6 90-883064R02 JULY 2006

 Clamp/Swivel Brackets and Driveshaft Housing

Swivel Bracket
Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
1 1 Link rod
2 1 Screw (1-1/2 in.) 27.0 20
3 1 Washer Non handle
4 2 Washer
5 2 Nut (0.375-24) See Note
6 1 Puck
7 1 Bushing
8 1 Swivel bracket
9 2 Bearing
10 2 Grease fitting (Quantity 3 required on Handle Versions)
11 1 Decal - Co-Pilot
12 1 Decal - Serial overlaminate
13 1 Bushing (Lower)
14 1 Seal
1 Screw (M8 x 10) (Handle)
15
1 Screw (M8 x 25) (Non handle)
16 1 Seal

NOTE: Torque nut to 13.5 Nm (120 lb. in.) then back off 1/4 turn.

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

90-883064R02 JULY 2006 Page 5A-7

Clamp/Swivel Brackets and Driveshaft Housing

Driveshaft Housing

1
16

6
8 7
5

25

4
19

20
15 9

21

24
10
23

11 22
13
12

14

17

18

Page 5A-8 90-883064R02 JULY 2006

 Clamp/Swivel Brackets and Driveshaft Housing

Driveshaft Housing
Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
1 1 Seal - Water tube
1 Driveshaft housing (Short)
2
1 Driveshaft housing (Long)
1 Exhaust pipe (Short)
3
1 Exhaust pipe (Long)
4 8 Screw - Adapter plate 45 33
5 5 Screw (M8 x 45) 45 33
6 1 Drain plug 23.5 17.5
7 1 Gasket
8 2 Bumper
9 1 Grommet (Long)
1 Stud (Non Bigfoot) 16 12
10
1 Stud (Bigfoot) 16 12
11 1 Washer
12 1 Nut 54.5 40
1 Water tube (Short)
13
1 Water tube (Long)
14 1 Guide
15 1 Bumper (Long)
16 1 Driveshaft housing
17 1 Plate
18 1 Screw (M10 x 25)
19 1 Speedometer pickup Bigfoot
20 1 Connector
21 1 Fitting
22 1 Spacer
23 1 Coupling
24 1 Bushing
25 2 Washer

90-883064R02 JULY 2006 Page 5A-9

Clamp/Swivel Brackets and Driveshaft Housing

Adapter Plate

Page 5A-10 90-883064R02 JULY 2006

 Clamp/Swivel Brackets and Driveshaft Housing

Adapter Plate
Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
1 1 Dipstick
2 1 Dipstick tube
3 1 Seal
4 1 Adapter plate
5 1 Plug
6 1 Tubing (17 in.)
7 1 Fitting
8 AR Cable tie
9 2 Cable tie
10 1 Seal - driveshaft (Non Bigfoot)
1 Seal - driveshaft (Bigfoot)
11 1 Bushing (Non Bigfoot)
12 1 Plug - oil passage
13 1 Grommet (Non Bigfoot)
14 1 Gasket
15 1 O-ring
16 3 Screw (M6 x 20) 8.5 75
17 1 Body - Oil pressure relief 46 34
18 1 Plate - Top oil pickup
19 1 Hose - Oil pickup
20 1 Baffle
21 2 Clamp
22 1 Screw (M6 x 55) 17 150
23 1 Heat shield
24 5 Dowel pin
25 1 Elbow

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
4-Stroke 10W-30 Outboard
110 92-802833A1 92-802833Q1
Oil
Loctite 567 PST Pipe
9 92-809822 92-809822
Sealant

90-883064R02 JULY 2006 Page 5A-11

Clamp/Swivel Brackets and Driveshaft Housing

Steering Arm

1
2
7
4 3
10
6 8 11

5
12
95

13
14
95
22

23

24
95
25 15
94

26
20
27

21
17
28
16

30 29
19

18

Page 5A-12 90-883064R02 JULY 2006

 Clamp/Swivel Brackets and Driveshaft Housing

Steering Arm
Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
1 2 Nut 68 50
2 1 Strap
3 2 Mount
4 2 Washer (Bigfoot)
5 8 Screw (M6 x 20) 15 130
6 1 Bumper
7 1 Bumper (Bigfoot)
8 1 Retaining ring
9 1 Steering arm
10 1 Bracket
11 1 Tab washer Non handle
12 2 Screw (M10 x 30) 44 32.5
13 2 Screw (M12 x 154) 32.5 24
1 Spacer (Short)
14
1 Spacer (Long)
1 Swivel tube (Short)
15
1 Swivel tube (Long)
16 1 Ground strap
17 1 Ground strap
18 2 Screw (M10 x 105) 44 32.5
19 1 Bracket
20 3 Screw (Self-tapping) Drive tight
21 2 Nut 44 32.5
22 1 Nut (0.375-24)
23 1 Lever - Co-pilot
24 1 Washer
25 1 Rod (Threaded) Handle
26 1 Bracket plate
27 1 Disc
28 1 Plate
29 1 Disc
30 2 Screw (Hex shoulder) 8 70

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

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

90-883064R02 JULY 2006 Page 5A-13

Clamp/Swivel Brackets and Driveshaft Housing

Bottom Cowl

Page 5A-14 90-883064R02 JULY 2006

 Clamp/Swivel Brackets and Driveshaft Housing

Bottom Cowl
Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
1 Bottom cowl (Short - Port)
1
1 Bottom cowl (Long - Port)
1 Bottom cowl (Short - Starboard)
2
1 Bottom cowl (Long - Starboard)
3 6 Screw (M6x 30) 7 60
4 1 Washer
5 1 Seal
6 1 Washer
7 1 Gasket
8 1 Screw (M6 x 60) 7 60
9 1 Fitting - tell tale
10 1 Boot
11 2 Cable tie
12 1 Lever - Cowl latch
13 2 Bushing
14 2 Wave washer
15 1 Latch hook
16 1 Screw (M6 x 16) 7 60
1 Grommet (Non Power Trim)
17
1 Grommet (Split - Power Trim)
18 1 Plug - Trim switch (Non Power Trim)
19 1 Switch (Power Trim)
20 1 Retainer
21 1 Grommet

90-883064R02 JULY 2006 Page 5A-15

 Power Trim

Mid-Section
Section 5B - Power Trim
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-2 Power Trim System Removal . . . . . . . . . . . . 5B-30
Power Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4 Power Trim Disassembly . . . . . . . . . . . . . . . . 5B-31
Theory Of Operation . . . . . . . . . . . . . . . . . . . . 5B-6 Trim Motor Removal . . . . . . . . . . . . . . . . . 5B-32
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-6 Pump and Components Removal . . . . . . 5B-32
Trimming Characteristics . . . . . . . . . . . . . 5B-6 Manifold Removal . . . . . . . . . . . . . . . . . . . 5B-33
Trailering Outboard . . . . . . . . . . . . . . . . . . 5B-7 Shock Rod Removal . . . . . . . . . . . . . . . . . 5B-34
Tilting Outboard Up and Down Manually 5B-7 Shock Rod Disassembly . . . . . . . . . . . . . . . . 5B-34
Power Trim Flow Diagrams . . . . . . . . . . . . . . 5B-8 Memory Piston Removal . . . . . . . . . . . . . 5B-37
Trim Up Circuit . . . . . . . . . . . . . . . . . . . . . . 5B-8 Cleaning/Inspection/Repair . . . . . . . . . . . . . . 5B-38
Trim Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-9 Trim Motor Electrical Tests . . . . . . . . . . . . 5B-38
Tilt Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-10 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-39

5
Tilt Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-11 O-ring and Seal Placement . . . . . . . . . . . 5B-39
Maximum Tilt . . . . . . . . . . . . . . . . . . . . . . . 5B-12 O-ring Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-40
Down Circuit . . . . . . . . . . . . . . . . . . . . . . . . 5B-14 O-ring Description and Sizes . . . . . . . . . . . . . 5B-41
Down Mode . . . . . . . . . . . . . . . . . . . . . . . . . 5B-15 Power Trim Reassembly . . . . . . . . . . . . . . . . 5B-42 B
Shock Function Up . . . . . . . . . . . . . . . . . . 5B-16 Shock Rod Reassembly . . . . . . . . . . . . . . 5B-42
Shock Function Return . . . . . . . . . . . . . . . 5B-18 Shock Rod Installation . . . . . . . . . . . . . . . 5B-44
Manual Release . . . . . . . . . . . . . . . . . . . . . 5B-20 Trim Limit Assembly Installation . . . . . . . 5B-45
Manual Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-21 Manual Release Valve Installation . . . . . 5B-45
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 5B-23 Manifold Installation . . . . . . . . . . . . . . . . . . 5B-46
Preliminary Checks . . . . . . . . . . . . . . . . . . 5B-23 Oil Pump Installation . . . . . . . . . . . . . . . . . 5B-47
Hydraulic System Troubleshooting Pressure Operated Assembly Installation 5B-48
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . 5B-24 Reservoir/Motor Installation . . . . . . . . . . . 5B-49
Troubleshooting the Power Trim Bleeding Power Trim Unit . . . . . . . . . . . . . 5B-50
Electrical System . . . . . . . . . . . . . . . . . . . 5B-28 Installation of Power Trim System . . . . . . . . 5B-51

90-883064R02 JULY 2006 Page 5B-1

Power Trim

Special Tools
1. Spanner Wrench (P/N 91-74951)

2. Lock-Ring Pliers (Snap-On [P/N SRP2] obtain locally)

3. Expanding Rod (Snap-On [P/N CG 41-11] obtain locally)

4. Collet (Snap-On [P/N CG 41-14] obtain locally)

5. Torch Lamp (P/N 91-63209)

Page 5B-2 90-883064R02 JULY 2006

 Power Trim

Notes:

90-883064R02 JULY 2006 Page 5B-3

Power Trim

Power Trim

17
19

2
4
12

16
8 9

5
13

6 15
6 11
11 11 7

6 6 11
11 11
17
11 14

10
18 15
11

Page 5B-4 90-883064R02 JULY 2006

 Power Trim

Power Trim
Torque
Ref.
Ref
No. QTY. Description Nm lb. in. lb. ft.
-- 1 Power trim pump
1 1 Shock rod kit
2 1 Memory piston assembly
3 1 O-ring rebuild kit
4 2 O-ring
5 1 Cylinder assembly
1 Trim limit valve kit (Non Bigfoot)
6
1 Trim limit valve kit (Bigfoot)
7 1 Pump assembly
8 1 Motor kit
9 1 Reservoir plug
10 1 Manual release assembly
11 1 Manifold kit 7.9 70
12 1 Screw kit (Motor) 9.0 80
13 1 Driveshaft
14 1 Filter kit
15 1 P.O. Check assembly kit
16 1 Cable
-- 1 O-ring kit (Complete trim)
17 2 Trilobe pin
18 1 Anchor pin
19 1 Pin

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

66 Loctite 242 92-809821 92-809821

90-883064R02 JULY 2006 Page 5B-5

Power Trim

Theory Of Operation
The power trim system consists of an electric motor, pressurized fluid reservoir, pump, and
trim cylinder.
The remote control (or trim panel) is equipped with a switch that is used for trimming the
outboard up and down, and for tilting the outboard for shallow water operation at slow speed,
or for trailering. The outboard can be trimmed up or down while the engine is under power
or when the engine is not running.

Adjustments
Trimming Characteristics
NOTE: Because varying hull designs react differently in various degrees of rough water, it
is recommended to experiment with trim positions to determine whether trimming up or
down will improve the ride in rough water.
When trimming the outboard from a mid-trim position (trim tab in neutral, straight fore and
aft position), the following results can be expected:
TRIMMING OUTBOARD UP (OUT)

WARNING
Excessive trim out may reduce the stability of some high speed hulls. To correct
instability at high speed, reduce the power gradually and trim the motor in slightly
before resuming high speed operation. Rapid reduction in power will cause a
sudden change of steering torque and may cause additional momentary boat
instability.
• Will lift bow of boat, generally increasing top speed.
• Transfers steering torque harder to the left on installations below 58.42 cm (23 in.)
transom height.
• Increases clearance over submerged objects.
• In excess, can cause porpoising and/or ventilation.
• In excess, can cause insufficient water supply to the water pump resulting in serious
water pump, and/or powerhead overheating damage.

WARNING
Excessive engine trim angle will result in insufficient water supply to the water
pump causing water pump, and/or powerhead overheating damage. Ensure the
water level is above the gear housing water intake holes whenever the engine is
running.
The operating up circuit will actuate the up relay located under the engine cowl, and close
the electric motor circuit. The electric motor will drive the pump, thus forcing automatic
transmission fluid through the internal passageways into the up side of the trim cylinder.
The trim cylinder/trim rod will position the engine at the desired trim angle within the 20°
maximum trim range. The power trim system is designed so the engine cannot be trimmed
beyond the 20° maximum trim angle as long as the engine RPM is above 2000 RPM.
The engine can be raised beyond the 20° maximum trim angle for shallow water operation,
by keeping the engine RPM below 2000 RPM. If the engine RPM increases above 2000
RPM, the thrust created by the propeller when deep enough in the water, will cause the trim
system to automatically lower the engine back to the 20° maximum trim angle.

Page 5B-6 90-883064R02 JULY 2006

 Power Trim

TRIMMING OUTBOARD DOWN (IN)

WARNING
Excessive speed at minimum trim in may cause undesirable and/or unsafe steering
conditions. Each boat should be tested for handling characteristics after any
adjustment is made to the tilt pin angle.
• Will help planing off, particularly with a heavy load.
• Usually improves the ride in choppy water.
• In excess, can cause the boat to veer to the left or right (bow steer).
• Transfers steering torque harder to the right (or less to the left).
• Improves planing speed acceleration (by moving tilt pin one hole closer to the transom).
Operating the down circuit will actuate the down relay located under the engine cowl and
close the electric motor circuit. The motor will run in the opposite direction of the up circuit.
The electric motor will drive the pump, forcing automatic transmission fluid through internal
passageways into the down side of the trim cylinder. The trim rod will move the engine
downward to the desired angle.
Trailering Outboard
WARNING
Excessive engine trim angle will result in insufficient water supply to the water
pump causing water pump, and/or powerhead overheating damage. Ensure the
water level is above the gear housing water intake holes whenever the engine is
running.
While operating the up circuit, the cylinder rod will continue to tilt the outboard to a full up
position for trailering.
Tilting Outboard Up and Down Manually
WARNING
Before loosening the manual release valve, ensure all persons are clear of the
engine, as the engine will drop to the full down position when the valve is loosened.
With the power trim installed, the outboard can be raised or lowered manually by opening
the manual release valve three to four turns counterclockwise.

55170

a - Manual release valve

90-883064R02 JULY 2006 Page 5B-7

Power Trim

Power Trim Flow Diagrams

Trim Up Circuit

a b

x c

d
l
j
i k
v e
u h
m n
g f g
t
y
o
p
z

s r
q

a - Piston rod n - Up circuit pressure operated valve

b - End cap o - Manifold reverse suction valve
c - Electric motor p - Manual release valve
d - Reservoir oil q - Manifold
e - Down circuit pressure relief valve r - Tilt relief valve
f - Down circuit pressure operated valve s - Tilt relief piston
g - Filter (2 shown for clarity) t - Memory piston
h - Shock return valve u - Shock piston
i - Up circuit suction port v - Impact relief valve
j - Oil pump w - Cylinder
k - Down circuit suction port x - Return oil
l - Oil fill cap y - Oil under pressure
m - Shuttle valve z - Filtered supply oil

Page 5B-8 90-883064R02 JULY 2006

 Power Trim

Power Trim
Up pressure 30 - 60 hp 11204 kPa (1625 psi) minimum
Impact relief pressure #22 30 - 60 hp 6067 - 7584 kPa (880 - 1110 psi)
30 - 60 hp 1724 - 2758 kPa (250 - 400 psi)
Tilt relief pressure
40 - 60 hp 3447 - 4826 kPa (540 - 990 psi)

Trim Up
When the trim switch is activated in the up position, the electric motor begins to rotate the
oil pump gears. The oil pump draws a small amount of oil through the filter and through the
up circuit suction port. The oil pump gear rotation forces oil into the passages for the up
circuit. Oil, under pressure, will slide the shuttle valve against the down circuit pressure
operated valve. The shuttle valve will mechanically open the down pressure operated valve,
allowing oil from the down cavity of the trim cylinder to flow into the oil pump. This returning
oil from the down cavity will supply most of the oil required for the up circuit. Oil in the up
circuit is blocked from returning into the reservoir by the ball inside the down circuit suction
port. The pressure of the oil will force the up circuit pressure operated valve to open allowing
the oil to enter the passages inside the manifold leading to the trim cylinder up cavity. Oil
is blocked from all other passages by the closed manual release valve. Oil under pressure
will enter the trim cylinder below the memory piston. With an increasing amount of oil
entering the cylinder, the memory piston contacts the shock piston, and forces the piston
rod up and out, raising the outboard motor. Oil on the top of the shock piston exits through
a passage running down alongside the cylinder, and enters the manifold passages. The oil
is drawn back into the pump through the open down circuit pressure operated valve and
enters the pump as supply for the up circuit.

90-883064R02 JULY 2006 Page 5B-9

Power Trim

Tilt Circuit

a b

c
x

v
u
h
d j l
i k
t
e
f
g m n
g

o
p
z
y

s r

a - Piston rod n - Up circuit pressure operated valve

b - End cap o - Manifold reverse suction valve
c - Electric motor p - Manual release valve
d - Reservoir oil q - Manifold
e - Down circuit pressure relief valve r - Tilt relief valve
f - Down circuit pressure operated valve s - Tilt relief piston
g - Filter (2 shown for clarity) t - Memory piston
h - Shock return valve u - Shock piston
i - Up circuit suction port v - Impact relief valve
j - Oil pump w - Cylinder
k - Down circuit suction port x - Return oil
l - Oil fill cap y - Oil under pressure
m - Shuttle valve z - Filtered supply oil

Page 5B-10 90-883064R02 JULY 2006

 Power Trim

Power Trim
Up pressure 30 - 60 hp 11204 kPa (1625 psi) minimum
Impact relief pressure #22 30 - 60 hp 6067 - 7584 kPa (880 - 1110 psi)
30 - 60 hp 1724 - 2758 kPa (250 - 400 psi)
Tilt relief pressure
40 - 60 hp 3447 - 4826 kPa (540 - 990 psi)

Tilt Up
In the up mode, as the piston rod extends from the cylinder, the memory piston clears or
uncovers the pressure relief passage. Oil from the up cavity will enter this passage, and if
required, causes the tilt relief piston to open the tilt pressure relief valve. This valve lowers
the amount of pressure available to lift the outboard motor. With the engine in forward gear,
and at high engine RPM, the oil pressure available will not be able to overcome the propeller
thrust, limiting the trim range to below the pressure relief orifice. When the engine RPM falls,
or if the engine is not in forward gear, the oil pressure is available to extend the piston rod
up into the tilt range.

90-883064R02 JULY 2006 Page 5B-11

Power Trim

Maximum Tilt

a b
v
u h
y
t
c

d j l
i k

e
f m n
g g

o
z p

s r
q

a - Piston rod n - Up circuit pressure operated valve

b - End cap o - Manifold reverse suction valve
c - Electric motor p - Manual release valve
d - Reservoir oil q - Manifold
e - Down circuit pressure relief valve r - Tilt relief valve
f - Down circuit pressure operated valve s - Tilt relief piston
g - Filter (2 shown for clarity) t - Memory piston
h - Shock return valve u - Shock piston
i - Up circuit suction port v - Impact relief valve
j - Oil pump w - Cylinder
k - Down circuit suction port x - Return oil
l - Oil fill cap y - Oil under pressure
m - Shuttle valve z - Filtered supply oil

Page 5B-12 90-883064R02 JULY 2006

 Power Trim

Power Trim
Up pressure 30 - 60 hp 11204 kPa (1625 psi) minimum
Impact relief pressure #22 30 - 60 hp 6067 - 7584 kPa (880 - 1110 psi)
30 - 60 hp 1724 - 2758 kPa (250 - 400 psi)
Tilt relief pressure
40 - 60 hp 3447 - 4826 kPa (540 - 990 psi)

Maximum Tilt
With the piston rod at maximum travel, and due to no rod movement, the pressure inside
of the trim cylinder will increase to the pressure required to move the tilt relief piston. The
tilt relief piston’s pin opens the tilt relief valve. Up pressure flows into the trim relief passage,
and returns back into the reservoir.

90-883064R02 JULY 2006 Page 5B-13

Power Trim

Down Circuit

a b

c
x

d
i j l
k

e z

u v f m n
h g
g
t
o
p

y s r

a - Piston rod n - Up circuit pressure operated valve

b - End cap o - Manifold reverse suction valve
c - Electric motor p - Manual release valve
d - Reservoir oil q - Manifold
e - Down circuit pressure relief valve r - Tilt relief valve
f - Down circuit pressure operated valve s - Tilt relief piston
g - Filter (2 shown for clarity) t - Memory piston
h - Shock return valve u - Shock piston
i - Up circuit suction port v - Impact relief valve
j - Oil pump w - Cylinder
k - Down circuit suction port x - Return oil
l - Oil fill cap y - Oil under pressure
m - Shuttle valve z - Filtered supply oil

Page 5B-14 90-883064R02 JULY 2006

 Power Trim

Power Trim
Up pressure 30 - 60 hp 11204 kPa (1625 psi) minimum
Impact relief pressure #22 30 - 60 hp 6067 - 7584 kPa (880 - 1110 psi)
30 - 60 hp 1724 - 2758 kPa (250 - 400 psi)
Tilt relief pressure
40 - 60 hp 3447 - 4826 kPa (540 - 990 psi)

Down Mode
When the trim switch is activated in the down position, the electric motor will rotate the pump
in the opposite direction. With the oil pump gears rotating backwards, the flow of oil is
reversed. Oil is drawn through the filter, through the down circuit suction port, and into the
oil pump. The pump forces pressurized oil into the down passages. Oil will slide the shuttle
valve into the up circuit pressure operated valve. The shuttle valve will mechanically open
the up circuit pressure operated valve, and allow oil from the up cavity of the trim cylinder to
return into the oil pump. This returning oil, from the up cavity, will supply the oil required for
the down circuit. The oil is blocked from returning into the reservoir by the ball inside the up
circuit suction port. Oil under pressure opens the down circuit pressure operated valve, and
enters the down passages inside of the manifold. The manifold passage connects into the
trim cylinder passage leading to the top of the cylinder. The cavity inside the cylinder, above
the shock piston, is the down cavity. As the down cavity fills with oil, the piston rod retracts
into the cylinder lowering the outboard motor. Oil from the up cavity exits the cylinder, and
is drawn back into the pump through the open up circuit pressure operated valve. When the
piston rod reaches full travel, the oil pressure inside the down circuit will rise until the down
circuit pressure relief valve opens, bypassing oil back into the reservoir. When the trim
button is released, and the oil pump stops supplying pressure, both of the pressure operated
valves will close, and if open, the down pressure relief valve will close. The closed valves will
lock the fluid on either side of the shock piston, and memory piston, holding the outboard
motor in position.

90-883064R02 JULY 2006 Page 5B-15

Power Trim

Shock Function Up

a b

x c

v
u h

d l
j
t i k
e
f n
g m
g

o
p

s r
q

a - Piston rod n - Up circuit pressure operated valve

b - End cap o - Manifold reverse suction valve
c - Electric motor p - Manual release valve
d - Reservoir oil q - Manifold
e - Down circuit pressure relief valve r - Tilt relief valve
f - Down circuit pressure operated valve s - Tilt relief piston
g - Filter (2 shown for clarity) t - Memory piston
h - Shock return valve u - Shock piston
i - Up circuit suction port v - Impact relief valve
j - Oil pump w - Cylinder
k - Down circuit suction port x - Return oil
l - Oil fill cap y - Oil under pressure
m - Shuttle valve

Page 5B-16 90-883064R02 JULY 2006

 Power Trim

Power Trim
Up pressure 30 - 60 hp 11204 kPa (1625 psi) minimum
Impact relief pressure #22 30 - 60 hp 6067 - 7584 kPa (880 - 1110 psi)
30 - 60 hp 1724 - 2758 kPa (250 - 400 psi)
Tilt relief pressure
40 - 60 hp 3447 - 4826 kPa (540 - 990 psi)

Shock Function Up
Oil inside the down cavity is locked in a static position by the closed down circuit pressure
operated valve, the manual release valve, and the manifold reverse suction valve. If the
outboard strikes an underwater object while in forward gear, the piston rod will try to rapidly
extend from the cylinder, and the pressure increases inside the trim cylinder down cavity,
and connecting passages. When the pressure increases to the level required, the impact
relief valves, located inside the shock piston, will open, and allow the fluid to pass through
it. As the fluid passes through the piston, the piston rod will extend from the trim cylinder.
The memory piston is held in position by vacuum created by the oil in the up cavity being
locked in a static position. Therefore, oil passing through the shock piston is trapped
between the memory piston and shock piston.

90-883064R02 JULY 2006 Page 5B-17

Power Trim

Shock Function Return

a b

x
c

v
h
u

y
d l
t i j k

e
f
m n
g
g

o
p

s r
q

a - Piston rod n - Up circuit pressure operated valve

b - End cap o - Manifold reverse suction valve
c - Electric motor p - Manual release valve
d - Reservoir oil q - Manifold
e - Down circuit pressure relief valve r - Tilt relief valve
f - Down circuit pressure operated valve s - Tilt relief piston
g - Filter (2 shown for clarity) t - Memory piston
h - Shock return valve u - Shock piston
i - Up circuit suction port v - Impact relief valve
j - Oil pump w - Cylinder
k - Down circuit suction port x - Return oil
l - Oil fill cap y - Oil under pressure
m - Shuttle valve

Page 5B-18 90-883064R02 JULY 2006

 Power Trim

Power Trim
Up pressure 30 - 60 hp 11204 kPa (1625 psi) minimum
Impact relief pressure #22 30 - 60 hp 6067 - 7584 kPa (880 - 1110 psi)
30 - 60 hp 1724 - 2758 kPa (250 - 400 psi)
Tilt relief pressure
40 - 60 hp 3447 - 4826 kPa (540 - 990 psi)

Shock Function Return

After the engine clears the underwater object, the weight of the engine will increase the oil
pressure between the memory piston, and shock piston to the level required to open the
shock return valve inside the shock piston, allowing the oil to bleed back through the shock
piston into the down cavity. If required, additional oil will enter the down cavity through the
manifold reverse suction valve. This will return the engine back against the memory piston,
and into the original running position.

90-883064R02 JULY 2006 Page 5B-19

Power Trim

Manual Release

a b

x c

v
h d
u l
i j k
t
e
f
m n
g g

o
p

s r
q

a - Piston rod n - Up circuit pressure operated valve

b - End cap o - Manifold reverse suction valve
c - Electric motor p - Manual release valve
d - Reservoir oil q - Manifold
e - Down circuit pressure relief valve r - Tilt relief valve
f - Down circuit pressure operated valve s - Tilt relief piston
g - Filter (2 shown for clarity) t - Memory piston
h - Shock return valve u - Shock piston
i - Up circuit suction port v - Impact relief valve
j - Oil pump w - Cylinder
k - Down circuit suction port x - Return oil
l - Oil fill cap
m - Shuttle valve

Page 5B-20 90-883064R02 JULY 2006

 Power Trim

Power Trim
Up pressure 30 - 60 hp 11204 kPa (1625 psi) minimum
Impact relief pressure #22 30 - 60 hp 6067 - 7584 kPa (880 - 1110 psi)
30 - 60 hp 1724 - 2758 kPa (250 - 400 psi)
Tilt relief pressure
40 - 60 hp 3447 - 4826 kPa (540 - 990 psi)
Down pressure 3620 - 6067 kPa (525 - 880 psi)

Manual Tilt
To manually tilt the outboard engine, the owner will need to back out the manual release
valve three to four turns. With the valve backed out, the internal passages inside the
manifold are connected together. These passages connect both the cylinder down and up
cavities together, along with the reservoir, allowing the engine to be raised or lowered.
Piston rod movement will continue until the manual release valve is closed, locking the fluid
inside of the cylinder and manifold.

90-883064R02 JULY 2006 Page 5B-21

Power Trim

Notes:

Page 5B-22 90-883064R02 JULY 2006

 Power Trim

Troubleshooting
Support the outboard with the tilt lock pin when servicing the power trim system.
IMPORTANT: After debris or failed components have been found during the
troubleshooting procedure, it is recommended that the unit be disassembled
completely and all O-rings be replaced. Check ball valve components and castings
must be cleaned using engine cleaner, and compressed air or replaced prior to
reassembly.
IMPORTANT: Power trim system is pressurized. The outboard must be in the full up
position, trim rod fully extended, prior to fill/drain plug, or manual release valve
removal.
Refer to instructions following if disassembly is required when servicing.
Follow preliminary checks before proceeding to troubleshooting flow diagrams following.
Preliminary Checks
IMPORTANT: Operate power trim system after each check to see if problem has been
corrected. If problem has not been corrected proceed to next check.
1. Check that manual release valve is tightened to full clockwise position.
2. Check trim pump fluid level with outboard in full up position and fill if necessary. Refer
to Section 5B - Bleeding Power Trim Unit.
3. Check for external leaks in the power trim system. Replace defective parts if leak is
found.
4. Outboard not holding tilted position - falls down to trim position, indicates debris or defec-
tive components in trim assembly. Clean or replace components as required.

90-883064R02 JULY 2006 Page 5B-23

Power Trim

Hydraulic System Troubleshooting Flow Chart

Outboard Will Not Hold Tilted Position

During Reverse And/Or Trails Out During
High Speed Deceleration.

Manual release Manual release valve and

Inspect manual release valve.
valve and O-ring O-rings appear to be O.K. -
damaged. Clean and reinstall manual
release valve.

Trim will not hold

Replace manual re- reverse thrust. Trim system holds re-
lease valve and O-rings. verse thrust. Testing
complete.

Trim system holds re- Remove and inspect pis-

verse thrust. Testing ton rod assembly for de- Shock piston appears
complete. bris and/or shock ball O.K. - Clean and reinstall
hang up. piston rod assembly.
Debris and/or shock
ball hang up identi-
fied.
Trim will not hold
reverse thrust. Trim system holds re-
verse thrust. Testing
complete.
Replace piston
rod assembly.
Remove PO check valve
assembly, inspect O-rings
and seals for damage.
Trim system holds re-
verse thrust. Testing
complete.

Debris and/or dam- PO check valve appears

age identified. O.K. - Clean and reinstall
PO check valve assem-
bly.

Replace PO check
valve assembly. Trim system holds
reverse thrust. Test-
ing complete.
Trim will not hold
reverse thrust.
Trim system holds re-
verse thrust. Testing
complete.
continued on next page

Page 5B-24 90-883064R02 JULY 2006

 Power Trim

Hydraulic System Troubleshooting Flow Chart

continued

Remove suction seat as-

sembly and inspect for
debris and/or damage.

Suction seat assembly

Debris and/or damage appears O.K. - Clean and
identified. reinstall suction seat
assembly.

Replace suction seat

assembly. Trim will not hold
reverse thrust. Trim system holds
reverse thrust. Test-
ing complete.
Trim system holds
reverse thrust. Test-
ing complete.
Replace trim system.

90-883064R02 JULY 2006 Page 5B-25

Power Trim

Hydraulic System Troubleshooting Flow Chart

Trim system leaks down with

manual release valve closed.

Manual release valve Inspect manual release valve. Manual release valve and O-
and O-ring damaged. rings appear to be O.K. - Clean
and reinstall manual release
valve.

Replace manual re- Trim system leaks

lease valve and down.
Trim system does
O-rings.
not leak down. Test-
ing complete.
Remove tilt relief valving
Trim system does and inspect O-rings and
not leak down. Test- seals for debris and/or
ing complete. damage.

Debris and/or dam- Tilt relief valving and O-rings

age identified. appear to be O.K. - Clean and
reinstall tilt relief valving.

Trim system leaks Trim system does

Replace tilt relief valving. down. not leak down. Test-
ing complete.

Trim system does Remove PO check valve

not leak down. Test- assembly, inspect O-
ing complete. rings and seals for dam-
age.

Debris and/or dam- PO check valve appears

age identified. O.K. - Clean and reinstall
PO check valve assem-
bly.
Replace PO check
valve assembly.
Trim system does
Trim system leaks down.
not leak down.
Testing complete.
Trim system does
continued on next page
not leak down. Test-
ing complete.

Page 5B-26 90-883064R02 JULY 2006

 Power Trim

Hydraulic System Troubleshooting Flow Chart

continued

Inspect memory pis-

ton O-ring and cylinder
bore.
Cylinder bore appears
Cylinder bore appears
rough and/or debris
smooth with no debris.
found in cylinder.

Replace memory pis-

ton and shock piston Trim leaks down.
O-rings.

Trim system does

not leak down. Test-
ing complete. Replace trim system.

90-883064R02 JULY 2006 Page 5B-27

Power Trim

Troubleshooting the Power Trim Electrical System

UP UP

a DN
b DN

BLU/WHT
GRN/WHT
BLU/WHT or PUR
GRN/WHT or GRN
RED
1 3
n

RED/PUR

RED
d
5 RED/PUR
5 RED 2
-- + 2 4

GRN/WHT
f i

BLU/WHT
e

g
l
33
GRN/WHT GRN/WHT
GRN
14 BLK
RED GRN/WHT
BLK

LT.BLU/WHT LT. BLU/WHT

BLUE
14 BLK
RED
BLK
LT. BLU/WHT

m
44
h 1
1
UP

j
DN
k

a - Remote control mounted trim switch h - Up relay

b - Panel mounted trim switch i - Solenoid
c - Fuse holder - Accessory j - Trim pump motor
d - Remote control wiring plug connector k - Cowl switch
e - Battery l - Solenoid
f - Starter bolt m - 3 pin connector
g - Down relay n - Main fuse holder - Fuse #3

Page 5B-28 90-883064R02 JULY 2006

 Power Trim

Troubleshooting the Power Trim Electrical System

Refer to the wiring diagram on the preceding page for location of wire connections.

Problem Possible Cause Remedy

Trim switch “UP” is inopera- 1. Open wire between wire connection (1) 1. Check for an open connection or cut
tive, but the cowl switch “UP” and trim switch. wire.
does operate. 2. Faulty trim switch. 2. Replace.

Cowl switch “UP” is inopera- 1. Open wire between wire connection (2) 1. Check for an open connection or cut
tive, but the trim switch “UP” and solenoid. wire.
does operate. 2. Faulty cowl switch. 2. Replace.

Trim switch “UP” and cowl 1. Open wire between wire connection (1) 1. Check for an open connection.
switch “UP” are both and the “Up” relay.
inoperative. 2. Open black wire between ground and 2. Check for an open connection.
“UP” relay.
3. Open red wire between solenoid and 3. Check for an open connection.
“UP” relay.
4. Faulty “UP” relay. 4. Replace.

Trim switch “DOWN” is inop- 1. Open wire between wire connection (3) 1. Check for an open connection or cut
erative, but the cowl switch and trim switch. wire.
“DOWN” does operate. 2. Faulty trim switch. 2. Replace.

Cowl switch “DOWN” is inop- 1. Open wire between wire connection (2) 1. Check for an open connection or cut
erative, but the trim switch and solenoid. wire.
“DOWN” does operate. 2. Faulty cowl switch. 2. Replace.

Trim switch “DOWN” and 1. Open wire between wire connection (3) 1. Check for an open connection.
cowl switch “DOWN” are and the “UP” relay.
both inoperative. 2. Open black wire between ground and 2. Check for an open connection.
“DOWN” relay.
3. Open red wire between solenoid and 3. Check for an open connection.
“DOWN” relay.
4. Faulty “DOWN” relay. 4. Replace.

Trim switch “UP” and 1. 20 AMP fuse blown. 1. Replace fuse. Locate the cause of
“DOWN” are both inopera- the blown fuse. Check electrical wiring
tive, but the cowl switch does for a shorted circuit.
operate. 2. Faulty trim switch. 2. Replace.
3. Wire is open between fuse holder and 3. Check for an open connection or cut
solenoid. wire.
4. Wire is open between fuse holder and 4. Check for a loose or corroded con-
trim switch. nection.

Trim switch and cowl switch 1. One of the trim pump motor wires is 1. Check wire connections (4) for loose
are both inoperative. open between the motor and the relays. or corroded condition.
2. Faulty trim pump motor. 2. If voltage is present at connections
(4) when the appropriate trim button is
pressed, then motor is faulty. Replace
motor.

Trim system operates (motor 1. The trim or cowl switch is shorted. 1. Replace.
runs) without pressing the
switches.

90-883064R02 JULY 2006 Page 5B-29

Power Trim

Power Trim System Removal

1. Tilt outboard to the full up position and support with tilt lock pin.
2. Disconnect the power trim wire harness and remove clamp.

b
a
c

55264
55464

a - Tilt lock pin

b - Power trim wire harness clamp
c - Harness

3. Remove the upper trilobe pin.

4. Drive out the upper pivot pin.
5. Remove the sacrificial anode.

a
b

c
55331

a - Upper trilobe pin

b - Upper pivot pin
c - Sacrificial anode

Page 5B-30 90-883064R02 JULY 2006

 Power Trim

6. Use a suitable punch to remove lower trilobe pin. Retain trilobe pin.
7. Use a suitable punch to drive out lower pivot pin.

a b 51144
51144

a - Lower trilobe pin

b - Lower pivot pin

Power Trim Disassembly

IMPORTANT: Power trim system is pressurized. The trim rod must be fully extended
prior to fill/drain plug, or manual release valve removal.
1. Remove the reservoir cap.
2. Remove the manual release valve assembly to drain oil.

55263

a - Reservoir cap
b - Manual release valve

90-883064R02 JULY 2006 Page 5B-31

Power Trim

Trim Motor Removal

1. Secure the power trim assembly in a soft jaw vise.
2. Remove four screws to remove the motor/reservoir. Remove reservoir seal, and coupler.

b
c

a - Screw (4)
b - Reservoir
c - Reservoir seal
d - Coupler
e - Manifold assembly
Pump and Components Removal
1. Remove the pressure operated plugs on the pump. Remove the spring and check valve/
poppet from both sides. Use special tool CG 41-11 and special tool CG 41-14 (available
through Snap-On) with 5/16″ end to remove spool.

a
b
c
d

e
d
c
b
a
a - Plug (2)
b - Spring (2)
c - Check valve/poppet (2)
d - Seat (2)
e - Spool
Special tool CG 41-11 Available through Snap-On
Special tool CG 41-14 Available through Snap-On

Page 5B-32 90-883064R02 JULY 2006

 Power Trim

IMPORTANT: Inspect the poppet assembly for debris in the area shown. If debris is
found on the poppet, replace poppet.
2. Remove three screws to remove the pump. Remove filter, and filter seal under the pump.
Remove the suction seat assembly.

a
d
b

a - Debris under valve tip

b - Rubber seat
c - Screw (3)
d - Filter seal
e - Filter
f - Suction seat assembly
Manifold Removal
1. Remove two screws to remove the manifold from the cylinder.
2. Remove the tilt relief components.

a
e
51146 51008

a - Screw (2) d - Spool housing

b - Spring e - Trim limit spool
c - Poppet

90-883064R02 JULY 2006 Page 5B-33

Power Trim

Shock Rod Removal

1. Unscrew the end cap assembly from the cylinder using the spanner wrench with 6.4 mm
x 8 mm (1/4 in. x 5/16 in.) long pegs.
2. Remove the shock rod assembly from the cylinder.

Spanner wrench 91-74951

Shock Rod Disassembly

NOTE: The only serviceable items on the shock rod assembly are the O-rings and wiper
ring. If the shock rod requires any other repair, replace the shock rod assembly.

b
b

a
a - End cap
b - O-ring (2)
c - Wiper ring

1. Place the shock rod assembly on a clean work surface.

2. Remove three screws and remove plate from the shock rod piston.

51143

a - Screw (3)
b - Plate
c - Shock rod piston

Page 5B-34 90-883064R02 JULY 2006

 Power Trim

3. Remove the check ball components from the shock rod piston.
4. Remove the O-ring from the shock rod piston.

c
b
a

d
51147

a - Spring (5)
b - Seat (5)
c - Ball (5)
d - O-ring

CAUTION
When removing the shock rod piston, the spanner wrench must have 6.4 mm x 8 mm
(1/4 in. x 5/16 in.) long pegs to avoid damage to the shock rod piston.
5. Place the shock rod into a soft jawed vise and apply heat to loosen the piston using a
torch lamp.
6. Loosen the shock rod piston using a spanner wrench with 6.4 mm x 8 mm (1/4 in. x
5/16 in.) long pegs.
7. Allow the shock rod piston to cool. Remove from the shock rod.
a
b

51146
51146

a - Spanner wrench
b - Shock rod piston
Spanner Wrench 91-74951
Torch Lamp 91-63209

90-883064R02 JULY 2006 Page 5B-35

Power Trim

8. Inspect the check valve for debris; clean debris from the check valve if found. If debris
cannot be cleaned from the check valve, replace the shock rod piston as an assembly.
9. Clean shock and components with compressed air.
10. Remove inner O-ring from the shock rod piston.

a b
51199

a - Shock rod piston

b - O-ring

11. Remove the cylinder end cap assembly from the shock rod.
12. Inspect the shock rod. If wiper has failed to keep shock rod clean, replace wiper.
13. Place end cap on a clean work surface.
14. Remove the rod wiper, inner O-ring, and outer O-ring.

c
b

51145

a - Rod wiper
b - Inner O-ring
c - Outer O-ring

Page 5B-36 90-883064R02 JULY 2006

 Power Trim

Memory Piston Removal

1. Remove the memory piston from the cylinder using one of two methods:
a. Using lock ring pliers or a suitable tool.

51144

b. Blowing compressed air into manual release valve hole.

Lock Ring Pliers Snap-On SRP2 (obtain locally)

WARNING
Memory piston cup may be expelled at a high velocity when air pressure is applied.
Failure to place cylinder as shown below could result in personal injury.
NOTE: Point cylinder opening down and away. Use a shop rag or towel to avoid damage
to the memory piston.
2. Remove O-ring from the memory piston.

a d
e

c
51144

55466

a - Adapter/air hose
b - Memory piston exit
c - Shop rag
d - O-ring
e - Memory piston

90-883064R02 JULY 2006 Page 5B-37

Power Trim

Cleaning/Inspection/Repair
IMPORTANT: Components must be dirt, and lint free. The slightest amount of debris
in the power trim system could cause system to malfunction.
Clean shock rod, and components with parts cleaner, and dry with compressed air.
It is recommended that all O-rings in the trim system be replaced.
Lubricate all O-rings with Power Trim Fluid. If not available, use automotive Automatic
Transmission Fluid (ATF).

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
Power Trim and Steering
114 92-802880A1 92-802880Q1
Fluid

Trim Motor Electrical Tests

1. Connect a 12 volt supply to motor leads. If motor fails to run, replace pump motor.
IMPORTANT: Trim motor is not serviceable. If motor fails to run, replace motor
assembly.

Page 5B-38 90-883064R02 JULY 2006

 Power Trim

Reassembly
O-ring and Seal Placement

22
33

22

20
8

9
19 10

21
21 11
12 13

14

18 9
15
10 16
9 17
8

90-883064R02 JULY 2006 Page 5B-39

Power Trim

O-ring Sizes
11 22
99

33

77

22 4

13
13

18 17 12 14
14

20 15

66
16
16

19
19 Cutaway View of O-ring
8
8

Width

10 21
21
10

11
11
O.D. I.D.

Page 5B-40 90-883064R02 JULY 2006

 Power Trim

O-ring Description and Sizes

O-ring Description O-ring I.D. O-ring O.D. O-ring Width
1 Wiper ring (412585)
2 Cylinder cap, inner12586) 17.04 mm (0.671 in.) 24.10 mm (0.949 in.) 3.53 mm (0.139 in.)
3 Cylinder cap8134) 47.34 mm (1.864 in.) 50.90 mm (2.004 in.) 1.78 mm (0.07 in.)
4 Shock piston2579) 40.64 mm (1.6 in.) 53.086 mm (2.02 in.) 5.334 mm (0.21 in.)
5 Piston bolt05797) 17.17 mm (0.676 in.) 20.726 mm (0.816 in.) 1.78 mm (0.07 in.)
6 Reservoir plug01271) 13.94 mm (0.549 in.) 19.17 mm (0.755 in.) 2.616 mm (0.103 in.)
7 Motor seal12599)
8 PO check plug06484) 12.42 mm (0.489 in.) 15.97 mm (0.629 in.) 1.78 mm (0.07 in.)
9 Poppet assembly74585)
10 PO check seat07328) 9.25 mm (0.364 in.) 12.80 mm (0.504 in.) 1.78 mm (0.07 in.)
11 Pump port 3.683 mm (0.145 in.) 7.239 mm (0.285 in.) 1.78 mm (0.07 in.)
12 Suction seat 6.07 mm (0.239 in.) 9.626 mm (0.379 in.) 1.78 mm (0.07 in.)
13 Filter seal12607)
14 Filter12590)
15 Manual release406483) 2.90 mm (0.114 in.) 6.451 mm (0.254 in.) 1.78 mm (0.07 in.)
16 Manual release06226) 4.47 mm (0.176 in.) 8.026 mm (0.316 in.) 1.78 mm (0.07 in.)
17 Manual release09051) 6.07 mm (0.239 in.) 9.626 mm (0.379 in.) 1.78 mm (0.07 in.)
18 Spool09051) 6.07 mm (0.239 in.) 9.626 mm (0.379 in.) 1.78 mm (0.07 in.)
19 Spool housing09005) 7.645 mm (0.301 in.) 11.20 mm (0.441 in.) 1.78 mm (0.07 in.)
20 Trim limit spool06483) 2.895 mm (0.114 in.) 6.451 mm (0.254 in.) 1.78 mm (0.07 in.)
21 Manifold405387) 5.283 mm (0.208 in.) 8.839 mm (0.348 in.) 1.78 mm (0.07 in.)
22 Memory piston412579) 40.64 mm (1.6 in.) 53.086 mm (2.02 in.) 5.334 mm (0.21 in.)

90-883064R02 JULY 2006 Page 5B-41

Power Trim

Power Trim Reassembly

IMPORTANT: Lubricate all O-rings with Power Trim Fluid. If not available, use
automotive Automatic Transmission Fluid (ATF).

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
Power Trim and Steering
114 92-802880A1 92-802880Q1
Fluid

Shock Rod Reassembly

1. Install the lubricated O-rings to the end cap.
2. Install the rod wiper.
3. Install the lubricated O-rings to the shock piston.

c
b
e f
51145

d 51199

a - Rod wiper
b - Inner O-ring
c - Outer O-ring
d - Shock piston
e - O-ring
f - O-ring

4. Clamp the shock rod in a soft jawed vise.

5. Position the cylinder end cap onto the rod as shown.

51146

Page 5B-42 90-883064R02 JULY 2006

 Power Trim

CAUTION
When installing the shock rod piston, the spanner wrench must have 6.4 mm x 8 mm
(1/4 in. x 5/16 in.) long pegs to avoid damage to the shock rod piston.
6. Apply Loctite 271 to threads on the shock rod. Install the shock rod piston.
7. Tighten the shock rod piston securely using the spanner wrench with 6.4 mm x 8 mm
(1/4 in. x 5/16 in.) long pegs. Tighten the shock rod piston to specification.
b
a

a - Shock rod piston

b - Spanner wrench
Spanner Wrench 91-74951

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

Description Nm lb. in. lb. ft.

Shock rod piston 122 90

8. Remove shock rod assembly from the vise.

9. Install ball, seat, and spring to the shock rod piston. Secure components with plate.

e
d
c
a

b 51147

a - Screw (3) d - Seat (5)

b - Plate e - Ball (5)
c - Spring (5)
Description Nm lb. in. lb. ft.
Screw 4 35

90-883064R02 JULY 2006 Page 5B-43

Power Trim

Shock Rod Installation

1. Place trim cylinder in a soft jawed vice.
2. Install lubricated O-ring to the memory piston and place into the cylinder. Push memory
piston all the way to the bottom.
3. Fill the cylinder 76.2 mm (3 in.) from the top of the cylinder, with Power Trim and Steering
Fluid. If not available, use automotive Automatic Transmission Fluid (ATF).
4. Install the shock rod into the cylinder until the power trim fluid flows through the oil blow
off ball passage. Fill remaining cylinder to just below the cylinder threads.

b
c

a - Memory piston
b - O-ring
c - Oil blow off ball passage

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
Power Trim and Steering
114 92-802880A1 92-802880Q1
Fluid

CAUTION
End cap must not make contact with the shock rod piston when tightening. The
shock rod piston must be positioned in the cylinder deep enough to avoid contact.
5. Tighten the end cap securely using spanner wrench with 6.4 mm x 8 mm (1/4 in. x
5/16 in.) long pegs. Tighten to the specified torque.

Spanner Wrench 91-74951

Description Nm lb. in. lb. ft.

End cap 61 45

Page 5B-44 90-883064R02 JULY 2006

 Power Trim

Trim Limit Assembly Installation

1. Lubricate all O-rings. Install spring, poppet, spool housing, and trim limit spool into the
manifold.

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
Power Trim and Steering
114 92-802880A1 92-802880Q1
Fluid

NOTE: There are three different size springs used in this manifold. The heavy spring is used
on 75-125 hp outboards. The medium spring is used on 40-60 hp Bigfoot outboards. The
light spring is used on 30-60 hp outboards.

or or a

d
51008

a - Spring
b - Poppet
c - Spool housing
d - Trim limit spool

Manual Release Valve Installation

1. Install E clip (if removed) and lubricated O-rings to the manual release valve.
2. Install the manual release valve assembly into the manifold.

b
a - Manifold
b - Manual release valve
c - E Clip

90-883064R02 JULY 2006 Page 5B-45

Power Trim

Manifold Installation
1. Install the dowel pin and two lubricated O-rings into the trim cylinder.

a - O-ring (2)
b - Dowel pin

2. Align the trim cylinder and pump/reservoir assembly together.

3. Install the two long screws and tighten to the specified torque.

c
b
51146

a - Trim cylinder assembly

b - Reservoir/manifold assembly
c - Screw (2)
Description Nm lb. in. lb. ft.
Screw 11 100

Page 5B-46 90-883064R02 JULY 2006

 Power Trim

Oil Pump Installation

1. Install spring, ball, lubricated O-ring, and plastic seat to the manifold.
2. Check to see that O-rings are placed on the bottom of the pump.
3. Install filter, and filter seal under the pump. Install pump onto the manifold. Tighten the
screws to the specified torque.

a - Screw (3)
b - Suction seat assembly
Description Nm lb. in. lb. ft.
Screw 8 70

90-883064R02 JULY 2006 Page 5B-47

Power Trim

Pressure Operated Assembly Installation

IMPORTANT: Inspect the poppet assembly for debris in the area shown. If debris is
found on the poppet, replace the poppet.
1. Lubricate the O-rings.
2. Install spool, seat with O-ring, check valve/poppet, spring, and plug with O-ring, into the
pump. Repeat for the other side. Tighten the plugs to the specified torque.

b c
d
e
f

g
f
e
d
c
a - Debris under valve tip
b - Rubber seat
c - Plug (2)
d - Spring (2)
e - Check valve/poppet (2)
f - Seat (2)
g - Spool
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
Power Trim and Steering
114 92-802880A1 92-802880Q1
Fluid

Description Nm lb. in. lb. ft.

Plug 13.5 120

Page 5B-48 90-883064R02 JULY 2006

 Power Trim

Reservoir/Motor Installation
1. Install the coupler into the top of the pump. Make sure the reservoir seal is in the
reservoir groove and place reservoir onto the pump/manifold assembly. Install the
ground strap under the screw shown. Tighten the screws to the specified torque.

a - Screw (4)
b - Reservoir
c - Reservoir seal
d - Coupler
e - Manifold assembly
f - Ground strap
Description Nm lb. in. lb. ft.
Screw 9 80

90-883064R02 JULY 2006 Page 5B-49

Power Trim

Bleeding Power Trim Unit

1. Secure the power trim unit in a soft jawed vise.
2. Fill reservoir to the bottom of the fill hole using Power Trim and Steering Fluid. If not
available, use automotive Automatic Transmission Fluid (ATF).
3. Close the manual release valve.
4. Using a 12 volt power supply, connect the positive lead to the blue trim motor wire and
the negative lead to the green trim motor wire, and drive the shock rod to the up position.
5. Connect the positive lead to the green trim motor wire, and the negative lead to the blue
trim motor wire, and drive the shock rod to the down position. Repeat steps 4 and 5 three
times.
6. Recheck fluid level. Add fluid if required and repeat cycle until the fluid level stays even
with the bottom of the fill hole.

114
a

55263

a - Reservoir plug/fill hole

b - Manual release valve
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
Power Trim and Steering
114 92-802880A1 92-802880Q1
Fluid

Page 5B-50 90-883064R02 JULY 2006

 Power Trim

Installation of Power Trim System

1. Lubricate lower pivot pin mounting holes with 2-4-C Marine Lubricant with Teflon.
2. Apply 2-4-C Marine Lubricant with Teflon to lower pivot pin, and start lower pivot pin into
the pivot pin bore.

95
51148

a - Lower pivot pin

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

3. Position the trim cylinder assembly bottom first, between clamp brackets.
4. Using a suitable punch, drive the lower pivot pin into the clamp bracket, and trim cylinder
assembly until pivot pin is flush with the outside surface.

95
a b
51147

55467

a - Trim cylinder assembly

b - Lower pivot pin
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

90-883064R02 JULY 2006 Page 5B-51

Power Trim

5. Using a suitable punch, drive lower trilobe pin into its hole until seated.

a - Lower trilobe pin

6. Apply 2-4-C Marine Lubricant with Teflon to the surface of the upper pivot pin, pivot pin
bore, and trim ram bore.

a
c

95

51148

a - Pivot pin
b - Pivot pin bore
c - Trim ram bore
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

Page 5B-52 90-883064R02 JULY 2006

 Power Trim

7. Using a suitable mallet, drive upper pivot pin into swivel bracket, and through trim ram
until pivot pin is flush with the swivel bracket.
8. Drive upper trilobe pin into its hole until seated.

51148
55464

a - Pivot pin
b - Swivel bracket
c - Trim ram
d - Upper trilobe pin

9. Install a sacrificial aluminum anode to the reservoir bracket placing the ground strap
between the bracket and anode, as shown.
10. Route trim harness through the clamp bracket, and cowling.

b
a
c 55465
55264

a - Sacrificial anode
b - Ground strap
c - Bracket
d - Trim harness

90-883064R02 JULY 2006 Page 5B-53

Power Trim

11. Secure trim harness with clamp, as shown.

55264

a - Clamp

Page 5B-54 90-883064R02 JULY 2006

 Manual Tilt Assist

Mid-Section
Section 5C - Manual Tilt Assist
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-2 Valve Block Removal . . . . . . . . . . . . . . . . . 5C-26
Manual Tilt Components . . . . . . . . . . . . . . . . . 5C-4 Memory Piston Removal . . . . . . . . . . . . . . 5C-27
Manual Trim Flow Diagrams . . . . . . . . . . . . . . 5C-6 Valve Block Disassembly . . . . . . . . . . . . . . . . . 5C-28
Up Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-29
Down Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 5C-8 O-ring Sizes . . . . . . . . . . . . . . . . . . . . . . . . . 5C-30
Slow Tilt Down Under High Thrust . . . . . . 5C-10 Manual Tilt System Cleaning and Inspection 5C-31
Under Water Strike (Valves Open) . . . . . . 5C-12 Manual Tilt System Reassembly . . . . . . . . . . 5C-31
Shock Function (Valve Closed) . . . . . . . . . 5C-14 Valve Block Reassembly . . . . . . . . . . . . . . 5C-32
Shock Function Return . . . . . . . . . . . . . . . . 5C-16 Valve Block Installation . . . . . . . . . . . . . . . . 5C-34
Hydraulic System Troubleshooting . . . . . . . . . 5C-18 Shock Rod Reassembly . . . . . . . . . . . . . . . 5C-35
Manual Tilt System Removal . . . . . . . . . . . . . . 5C-20 Shock Rod Installation and Fluid Filling
Manual Tilt System Disassembly . . . . . . . . . . 5C-22 Procedure - Option One . . . . . . . . . . . . . . 5C-37
Accumulator Removal . . . . . . . . . . . . . . . . .
Shock Rod Removal . . . . . . . . . . . . . . . . . .
5C-22
5C-23
Fluid Filling Procedure - Option Two . . . .
Manual Tilt System Installation . . . . . . . . . . . .
5C-39
5C-42
5
Shock Rod Disassembly . . . . . . . . . . . . . . . . . 5C-23 Manual Release Valve Adjustment . . . . . . 5C-45 C

90-883064R02 JULY 2006 Page 5C-1

Manual Tilt Assist

Special Tools
1. Spanner wrench (P/N 91-74951)

2. Lock-ring pliers (SRP2 - Available through Snap-On)

3. Torch lamp (P/N 91-63209)

Page 5C-2 90-883064R02 JULY 2006

 Manual Tilt Assist

Notes:

90-883064R02 JULY 2006 Page 5C-3

Manual Tilt Assist

Manual Tilt Components

95

95

Page 5C-4 90-883064R02 JULY 2006

 Manual Tilt Assist

Manual Tilt Components

Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
1 1 Shock rod assembly
2 1 Memory piston assembly
3 1 O-ring rebuild kit - Cylinder
4 2 O-ring
5 1 Cylinder assembly
6 1 Screw and seal kit
7 1 Accumulator assembly 47 35
8 1 Valve body assembly
9 1 Cam kit
10 1 Velocity valve kit
11 1 Check system repair kit
– 1 O-ring kit
12 1 Cable
13 2 Pin
14 2 Trilobe pin

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

7 Loctite 271 Threadlocker 92-809819 92-809819

90-883064R02 JULY 2006 Page 5C-5

Manual Tilt Assist

Manual Trim Flow Diagrams

Up Circuit

b
a

p
e
o

f
n
k
m

j i h g
l

a - Shock rod i - Down circuit slow transfer valve

b - End cap j - Up circuit fast transfer valve
c - Accumulator k - Surge valve
d - Accumulator piston l - Cylinder
e - Accumulator check valve m - Memory piston
f - Camshaft lever n - Shock piston
g - Manifold o - Shock return valve
h - Down circuit fast transfer valve p - Impact relief valve

Page 5C-6 90-883064R02 JULY 2006

 Manual Tilt Assist

Up Circuit
With the engine in the down position, the accumulator piston will be at the top of the
accumulator with the gas at maximum pressure. To raise the engine, the camshaft lever is
rotated all the way down. The internal shaft connected to the camshaft lever will move the
push rods opening the accumulator check valve, both fast transfer valves, and the down
circuit slow transfer valve. As the operator lifts the engine, oil under pressure inside the
accumulator will flow around both the slow transfer valve, and the down circuit fast transfer
valve. Oil flows into the bottom of the tilt cylinder forcing the memory piston into the shock
piston, and then forcing the shock rod up and out. Oil above the shock piston exits the
cylinder through an interconnecting passage alongside of the cylinder, and returns into the
manifold. Inside the manifold the oil flows past the groove in the surge valve, through the
up circuit fast transfer valve, and mixes with the oil flowing from the accumulator into the up
cavity. With the engine in the correct position, the camshaft lever is rotated up, and the push
rods allow the accumulator check valve, down circuit fast transfer valve, down circuit slow
transfer valve, and the up circuit fast transfer valve to close. The closed check valves
prevent the oil from traveling between cavities, and locks the engine into position.

90-883064R02 JULY 2006 Page 5C-7

Manual Tilt Assist

Down Circuit

b
a

p
e

f
n

m k

j i h g
l

a - Shock rod i - Down circuit slow transfer valve

b - End cap j - Up circuit fast transfer valve
c - Accumulator k - Surge valve
d - Accumulator piston l - Cylinder
e - Accumulator check valve m - Memory piston
f - Camshaft lever n - Shock piston
g - Manifold o - Shock return valve
h - Down circuit fast transfer valve p - Impact relief valve

Page 5C-8 90-883064R02 JULY 2006

 Manual Tilt Assist

Down Circuit
With the engine tilted up, the piston inside the accumulator piston will be at the bottom of
the accumulator, and the gas pressure is low. To lower the engine, the camshaft lever is
rotated down, the internal cam will cause the push rods to open the accumulator check
valve, both fast transfer valves, and the down circuit slow transfer valve. The operator will
have to press down on the engine cowl to overcome the pressure inside the cylinder. Fluid
will flow out of the bottom of the cylinder, past both the down circuit fast transfer valve, and
down circuit slow transfer valve. Fluid will flow past the up circuit fast transfer valve, surge
valve, and through the interconnecting passage into the top of the cylinder. Due to the shock
rod, the tilt cylinder cavities differ in volume. The extra fluid from the up cavity forced into
the accumulator, will cause the internal accumulator piston to compress the gas. With the
engine in the correct position, the camshaft lever is rotated up, and the push rods allow the
accumulator check valve, down circuit fast transfer valve, down circuit slow transfer valve,
and the up circuit fast transfer valve to close.

90-883064R02 JULY 2006 Page 5C-9

Manual Tilt Assist

Slow Tilt Down Under High Thrust

b
a

p f
e
o

n
k
m

j i h g
l

a - Shock rod i - Down circuit slow transfer valve

b - End cap j - Up circuit fast transfer valve
c - Accumulator k - Surge valve
d - Accumulator piston l - Cylinder
e - Accumulator check valve m - Memory piston
f - Camshaft lever n - Shock piston
g - Manifold o - Shock return valve
h - Down circuit fast transfer valve p - Impact relief valve

Page 5C-10 90-883064R02 JULY 2006

 Manual Tilt Assist

Slow Tilt Down Under High Thrust

To tilt the engine down under high thrust conditions when the propeller thrust forces the
shock rod down creating higher pressure below the memory piston, the camshaft lever is
rotated slightly downward. The internal shaft connected to the lever will open the down
circuit slow transfer valve allowing oil under pressure into the cavity around the shaft. The
higher oil pressure will open the up circuit fast transfer valve allowing oil from the bottom
of the cylinder to flow above the shock piston while lowering the engine. Additional oil will
flow into the accumulator as the internal pressure forces the accumulator check valve to
open. Oil flowing into the accumulator moves the accumulator piston, and compresses
the gas.

90-883064R02 JULY 2006 Page 5C-11

Manual Tilt Assist

Under Water Strike (Valves Open)

b
a

f
n
k
m

j i h g
l

a - Shock rod i - Down circuit slow transfer valve

b - End cap j - Up circuit fast transfer valve
c - Accumulator k - Surge valve
d - Accumulator piston l - Cylinder
e - Accumulator check valve m - Memory piston
f - Camshaft lever n - Shock piston
g - Manifold o - Shock return valve
h - Down circuit fast transfer valve p - Impact relief valve

Page 5C-12 90-883064R02 JULY 2006

 Manual Tilt Assist

Under Water Strike (Valves Open)

Should the drive unit strike a submerged object while in forward motion, the shock rod will
extend from the tilt cylinder. Fluid will attempt to exit the cylinder through the interconnecting
passage. The rapid fluid flow will increase the pressure below the surge valve, causing the
valve to move, closing the oil return passage back into the accumulator. Oil inside the up
cavity is locked in a static position by the closed surge valve. As the shock rod extends
outward, the pressure inside the up cavity will reach sufficient pressure to open the shock
valve which opens at 6067 - 7584 kPa (880 - 1110 psi). Oil will flow into the cavity created
as the shock rod, and shock piston moves away from the memory piston.

90-883064R02 JULY 2006 Page 5C-13

Manual Tilt Assist

Shock Function (Valve Closed)

b
a

o
e

n
f

k
m

j i h g
l

a - Shock rod i - Down circuit slow transfer valve

b - End cap j - Up circuit fast transfer valve
c - Accumulator k - Surge valve
d - Accumulator piston l - Cylinder
e - Accumulator check valve m - Memory piston
f - Camshaft lever n - Shock piston
g - Manifold o - Shock return valve
h - Down circuit fast transfer valve p - Impact relief valve

Page 5C-14 90-883064R02 JULY 2006

 Manual Tilt Assist

Power Trim
Accumulator gas pressure 2758 kPa (400 psi) minimum

Shock Function (Valves Closed)

Should the drive unit strike a submerged object while in forward motion, the shock rod will
extend from the cylinder. Oil inside the up cavity is locked in a static position by the closed
up circuit fast transfer valve, the closed down circuit slow transfer valve, and closed down
circuit fast transfer valve. Fluid will attempt to exit the cylinder through the interconnecting
passage back into the accumulator. The closed up circuit fast transfer valve will prevent the
fluid return. As the shock rod extends outward, the pressure inside the up cavity will reach
sufficient pressure to open the shock valve which opens at 6067 - 7584 kPa (880 - 1110 psi).
Oil will flow into the cavity created as the shock rod, and shock piston moves away from the
memory piston.

90-883064R02 JULY 2006 Page 5C-15

Manual Tilt Assist

Shock Function Return

b
a

o
e

n
f

k
m

j i h g
l

a - Shock rod i - Down circuit slow transfer valve

b - End cap j - Up circuit fast transfer valve
c - Accumulator k - Surge valve
d - Accumulator piston l - Cylinder
e - Accumulator check valve m - Memory piston
f - Camshaft lever n - Shock piston
g - Manifold o - Shock return valve
h - Down circuit fast transfer valve p - Impact relief valve

Page 5C-16 90-883064R02 JULY 2006

 Manual Tilt Assist

Shock Function Return

After the drive clears the object, the shock return valve will allow the oil to flow from between
the shock piston, and memory piston onto the down cavity as the drive returns to its original
running position.

90-883064R02 JULY 2006 Page 5C-17

Manual Tilt Assist

Hydraulic System Troubleshooting

Refer to disassembly/reassembly instructions following, if disassembly is required when
servicing.
IMPORTANT: After debris or failed components have been found during the
troubleshooting procedure, it is recommended that the unit be disassembled
completely, and all O-rings be replaced. Check ball components, and castings must
be cleaned using engine cleaner, and compressed air, or replaced prior to
reassembly.
Support outboard with tilt lock lever when servicing manual tilt system.
1. Check manual release cam adjustment. Cam must open, and close freely. Adjust cam
link rod as necessary.

51143

a - Link rod
b - Manual release lever
c - Accumulator

Page 5C-18 90-883064R02 JULY 2006

 Manual Tilt Assist

2. Check for external leaks in the manual tilt system. Replace defective parts if leak is
found.
IMPORTANT: If cut or damaged O-rings are found, inspect machined surfaces for
scoring, burrs, or debris.
3. Check for discharged accumulator. A pulling force of 47 - 68 Nm (35 - 50 lb. ft.), must
be attained when tilting the outboard from full down to full up position. If more than
68 Nm (50 lb. ft.) of force is required, replace the accumulator.
a

50431

a - Weight scale
b - Valve lever - open position

90-883064R02 JULY 2006 Page 5C-19

Manual Tilt Assist

Manual Tilt System Removal

CAUTION
Remove cowling, and remove all spark plug leads from spark plugs to prevent
accidental starting while servicing the outboard.

WARNING
Service or installation of the tilt system may result in loss of pressure in the shock
cylinder. If the outboard is not in the full down position, such loss of pressure will
cause the engine to fall to the full down position with a potential for damaging the
engine or causing personal injury. To avoid such injury, support the outboard in the
up position using the tilt lock lever.

WARNING
Manual tilt system is pressurized. Accumulator must be removed when shock rod
is in the full up position, prior to servicing, otherwise oil spray back may occur.

1. Support the outboard in the up position using the tilt lock lever.
2. Remove the link rod.

51143

a - Link rod
b - Accumulator

Page 5C-20 90-883064R02 JULY 2006

 Manual Tilt Assist

3. Position a piece of wood under the transom bracket instead of the tilt lock. This allows
for access of removing the pin. Use a suitable punch to remove the upper trilobe pin.
Retain the trilobe pin.
4. Position the tilt lock and remove the piece of wood.
5. Use a suitable punch to drive out the upper pivot pin.

c
b

51144
51144

a - Pivot pin
b - Tilt lock
c - Trilobe pin
d - Wood

6. Remove the sacrificial anode.

7. Use a punch to remove the lower trilobe pin. Retain the trilobe pin.
8. Use a suitable punch to drive out the lower pivot pin.

c
a 55331

a - Sacrificial anode
b - Trilobe pin
c - Pivot pin

90-883064R02 JULY 2006 Page 5C-21

Manual Tilt Assist

9. Tilt the upper end of the shock absorber assembly out from the clamp bracket, and remove
the assembly.

51144

a - Manual tilt system

Manual Tilt System Disassembly

NOTE: Accumulator contains a high pressure nitrogen charge and is not serviceable.
Replace if necessary.

WARNING
This tilt system is pressurized. Remove accumulator only when the shock rod is in
the full up position.

Accumulator Removal
1. Place the manual tilt system in a soft jawed vise. Position shock rod to full up position.
2. Open the camshaft valve. The valve will face down.
3. Loosen the velocity valve enough to drip. Wait until dripping stops. When fluid stops
dripping, loosen, and remove accumulator.
4. If the plunger can be compressed into the accumulator by hand, the accumulator is
defective. Replace the accumulator.

c 51143
51143

a - Accumulator c - Velocity valve

b - Cam lever d - Plunger

Page 5C-22 90-883064R02 JULY 2006

 Manual Tilt Assist

5. Remove the O-ring, conical spring, steel ball, and plunger.

a

b
c
d

51145

a - Conical spring
b - Steel ball
c - Plunger
d - O-ring

Shock Rod Removal

1. Unscrew the cylinder end cap assembly using a spanner wrench.
2. Remove the shock rod assembly from the cylinder.

51145

Spanner Wrench 91-74951

Shock Rod Disassembly

NOTE: Only the O-rings, and wiper ring are serviceable. If the shock rod requires any other
repair, replace the shock rod assembly.

a
a - End cap
b - O-ring (2)
c - Wiper ring

90-883064R02 JULY 2006 Page 5C-23

Manual Tilt Assist

1. Place the shock rod assembly on a clean work surface.

2. Remove three screws, and remove the plate from the shock rod piston.
a

b
c
51143

a - Screw (3)
b - Plate
c - Shock rod piston

3. Remove the check ball components from the shock rod piston.
4. Remove the O-ring.

c
b
a

d 51147

a - Spring (5)
b - Seat (5)
c - Ball (5)
d - O-ring

Page 5C-24 90-883064R02 JULY 2006

 Manual Tilt Assist

CAUTION
When removing the shock piston, the spanner wrench must have 6.4 mm x 8 mm
(1/4 in. x 5/16 in.) long pegs to avoid damage to the shock piston.
5. Place the shock rod into a soft jawed vise, and apply heat to loosen the piston using a
torch lamp.
6. Loosen the shock rod piston using a spanner wrench with 6.4 mm x 8 mm (1/4 in. x
5/16 in.) long pegs.
7. Allow the shock rod piston to cool. Remove from the shock rod.
a
b

91-74951
91-63209
a - Spanner wrench
b - Shock rod piston
Spanner Wrench 91-74951
Torch Lamp 91-63209

8. Inspect the check valve for debris; clean debris from the check valve if found. If debris
cannot be cleaned from the check valve, replace the shock piston as an assembly.
9. Clean the shock and components with compressed air.
10. Remove the inner O-ring.

b
a 51199

a - Shock piston
b - O-ring

90-883064R02 JULY 2006 Page 5C-25

Manual Tilt Assist

11. Remove the cylinder end cap assembly from the shock rod.
12. Inspect the shock. If the wiper located in the cap has failed to keep the rod clean, replace
the wiper.
13. Place the end cap on a clean work surface.
14. Remove the rod wiper, inner O-ring, and outer O-ring.

c
b

51147 51145

a - Rod wiper
b - Inner O-ring
c - Outer O-ring

Valve Block Removal

1. Remove two screws from the shock rod cylinder to separate the valve block.
2. Remove the O-rings and dowel pins.

e
b
aa

51148
c
51146

a - Screw
b - Valve block
c - Shock rod cylinder
d - O-ring (2)
e - Dowel pin (2)

Page 5C-26 90-883064R02 JULY 2006

 Manual Tilt Assist

Memory Piston Removal

1. Remove the memory piston from the cylinder using one of two methods:
a. Using the lock ring pliers.

Snap-On SRP2
51144

b. Blowing compressed air into center O-ring hole.

Lock ring pliers Snap-On SRP2 (obtain locally)

WARNING
The memory piston cup may be expelled at a high velocity when air pressure is
applied. Failure to place the cylinder as shown below could result in personal injury.
NOTE: Point cylinder opening down and away. Use a shop rag or towel to avoid damage
to the memory piston.
2. Remove the O-ring from the memory piston.

a
d

51144
55466

a - Adapter/air hose
b - Memory piston exit
c - Shop rag
d - O-ring
e - Memory piston

90-883064R02 JULY 2006 Page 5C-27

Manual Tilt Assist

Valve Block Disassembly

1. Remove the check retainer plug, and components.
2. Remove the hydraulic oil transfer valve plugs, and components.
3. Remove the surge valve assembly.

c
d
e
f
a

b 51142

a - Transfer valve plug assembly (2)

b - Check retainer plug or screw assembly
c - Spool
d - Spring
e - O-ring
f - Velocity valve

4. Remove the screw, and cam assembly.

e
d

b c
a

a - Spacer retainer clip

b - Retainer clip
c - Screw
d - Shaft seal
e - Cam

Page 5C-28 90-883064R02 JULY 2006

 Manual Tilt Assist

Reassembly

14

7
9
6
11 12

10

13

90-883064R02 JULY 2006 Page 5C-29

Manual Tilt Assist

O-ring Sizes

2 9

14
4

5 10

13 Cutaway View of O-ring

6 11

Width

7 12

O.D. I.D.

O-rings shown are actual size

Page 5C-30 90-883064R02 JULY 2006

 Manual Tilt Assist

O-RING DESCRIPTION AND SIZES

O-ring Description O-ring I.D. O-ring O.D. O-ring Width

1 Wiper ring
2 Cylinder cap, inner 17.04 mm (0.671 in.) 24.10 mm (0.949 in.) 3.53 mm (0.139 in.)
3 Cylinder cap 47.34 mm (1.864 in.) 50.90 mm (2.004 in.) 1.78 mm (0.07 in.)
4 Shock piston 40.64 mm (1.6 in.) 53.086 mm (2.02 in.) 5.334 mm (0.21 in.)
5 Piston bolt 17.17 mm (0.676 in.) 20.726 mm (0.816 in.) 1.78 mm (0.07 in.)
6 Manifold split line 5.283 mm (0.208 in.) 8.839 mm (0.348 in.) 1.78 mm (0.07 in.)
7 Slow valve 2.90 mm (0.114 in.) 6.451 mm (0.254 in.) 1.78 mm (0.07 in.)
8 Plug 12.42 mm (0.489 in.) 15.97 mm (0.629 in.) 1.78 mm (0.07 in.)
9 Accumulator 53.69 mm (2.114 in.) 57.25 mm (2.254 in.) 1.78 mm (0.07 in.)
10 Lip seal
11 Camshaft 7.645 mm (0.301 in.) 11.20 mm (0.441 in.) 1.78 mm (0.07 in.)
12 Back up ring
13 Surge valve02664) 7.645 mm (0.301 in.) 11.20 mm (0.441 in.) 1.78 mm (0.07 in.)
14 Memory piston 40.64 mm (1.6 in.) 53.086 mm (2.02 in.) 5.334 mm (0.21 in.)

Manual Tilt System Cleaning and Inspection

1. It is recommended that all O-rings exposed during disassembly be replaced.
2. Clean components, filter, and check valve seats using engine cleaner and compressed
air. Do not use cloth rags.
3. Inspect all machined surfaces for burrs or scoring to assure O-ring longevity.
4. Inspect the shock rod. If the scraper located in the cap has failed to keep the rod clean,
replace the scraper.

Manual Tilt System Reassembly

IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in tilt
system could cause system to malfunction.
Lubricate all O-rings during reassembly with Power Trim and Steering Fluid. If not available,
use automotive Automatic Transmission Fluid (ATF).

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
Power Trim and Steering
114 92-802880A1 92-802880Q1
Fluid

90-883064R02 JULY 2006 Page 5C-31

Manual Tilt Assist

Valve Block Reassembly

CAMSHAFT REASSEMBLY
IMPORTANT: Camshaft O-ring must be lubricated using 2-4-C Marine Lubricant with
Teflon.
1. Install the lubricated O-ring and back up seal to the cam.
2. Install the shaft seal in the valve block with the lips facing out.
3. Install the camshaft assembly in the valve block.
4. Secure the camshaft in place using the insulator, retainer plate, and screw. Tighten the
screw securely.

f g
e
d

c
b
a
95

a - Spacer retainer clip

b - Retainer clip
c - Screw
d - Shaft seal
e - O-ring
f - Back up seal
g - Cam
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

VALVE BODY CHECK REASSEMBLY

1. Install the lubricated O-ring, plunger, steel ball, and conical spring to the valve block.
a

b
c

51145

a - Conical spring
b - Steel ball
c - Plunger
d - O-ring

Page 5C-32 90-883064R02 JULY 2006

 Manual Tilt Assist

VELOCITY VALVE REASSEMBLY

1. Install the spool, spring, lubricated O-ring, and velocity valve assembly into the valve
block.
2. Tighten the velocity valve to the specified torque.

a
b
c
d

a - Spool
b - Spring
c - O-ring
d - Velocity valve
Description Nm lb. in. lb. ft.
Velocity valve 8.5 75

CHECK RETAINER REASSEMBLY

1. Install the plunger, large spring, ball, small spring, and plug into the valve block.

c
d
e 51142

a - Plunger
b - Spring - large
c - Ball
d - Spring - small
e - Plug

90-883064R02 JULY 2006 Page 5C-33

Manual Tilt Assist

VALVE PLUG REASSEMBLY

1. Install the plunger, steel ball, spring, lubricated O-ring, and screw plug. Tighten the
screw plugs to the specified torque.

c
d
e
51142

a - Plunger (2)
b - Steel ball (2)
c - Spring (2)
d - O-ring (2)
e - Screw plug (2)
Description Nm lb. in. lb. ft.
Screw plug (2) 8.5 75

Valve Block Installation

1. Install the lubricated O-rings and dowel pins.
2. Install the valve block to the shock rod cylinder. Insert screws to the shock rod cylinder
and tighten to the specified torque.

b c
1
d

e
51148 51146

a - O-ring (2)
b - Dowel pin (2)
c - Valve block
d - Screw (2)
e - Shock rod cylinder
Description Nm lb. in. lb. ft.
Screw (2) 11 100

Page 5C-34 90-883064R02 JULY 2006

 Manual Tilt Assist

Shock Rod Reassembly

1. Install the lubricated O-rings to the end cap.
2. Install the rod wiper.
3. Install the lubricated O-rings to the shock piston.

c e
b f
51145
d 51199

a - Rod wiper
b - Inner O-ring
c - Outer O-ring
d - Shock piston
e - O-ring
f - O-ring

4. Clamp the shock rod in a soft jawed vise.

5. Position the cylinder end cap onto the rod, as shown.

51146

90-883064R02 JULY 2006 Page 5C-35

Manual Tilt Assist

CAUTION
When installing the shock rod piston, the spanner wrench must have 6.4 mm x 8 mm
(1/4 in. x 5/16 in.) long pegs to avoid damage to shock rod piston.
6. Apply Loctite 271 Threadlocker to the threads on the shock rod.
7. Install the shock rod piston.
8. Tighten the shock rod piston securely using a spanner wrench with 6.4 mm x 8 mm
(1/4 in. x 5/16 in.) long pegs. Tighten to the specified torque.
a b

51146
a - Spanner wrench
b - Shock rod piston
Spanner wrench 91-74951

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

Description Nm lb. in. lb. ft.

Shock rod piston 122 90
9. Install the ball, seat, and spring to the shock rod piston.
10. Secure components with a plate. Tighten the screws to the specified torque.
11. Remove the shock rod assembly from the vise.

e
d

a c

b 51147

a - Screw (3)
b - Plate
c - Spring (5)
d - Seat (5)
e - Ball (5)
Description Nm lb. in. lb. ft.
Screw (3) 4 35

Page 5C-36 90-883064R02 JULY 2006

 Manual Tilt Assist

Shock Rod Installation and Fluid Filling Procedure - Option One

NOTE: There are two ways for the filling procedure. The first is the easiest, and less time
consuming.
1. Place the trim cylinder in a soft jawed vice.
2. With the manifold cam lever closed in the up position, fill the cylinder and manifold to
the top with Power Trim and Steering Fluid, or Automatic Transmission Fluid (ATF).
Allow the bubbles to disperse.
3. Install a lubricated O-ring to the memory piston.
4. Using lock ring pliers (obtain locally), set the memory piston in the top of the cylinder then
open the cam lever to the down position. Push the memory piston down just below the
cylinder threads. Close the cam lever to the up position.

51144

Lock ring pliers Snap-On SRP2 (obtain locally)

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
Power Trim and Steering
114 92-802880A1 92-802880Q1
Fluid

5. Fill the top of the cylinder again with fluid to the top, and install the shock rod assembly
on the top memory piston. Open the cam lever to the down position, and push the shock
rod assembly down to 1/8″ below the cylinder threads. Close the cam lever to the up
position.
6. Fill the top of the shock rod assembly with fluid to the top of the cylinder. Open the cam
lever to the down position, and thread the cylinder end cap down.

90-883064R02 JULY 2006 Page 5C-37

Manual Tilt Assist

7. Tighten the end cap securely using a spanner wrench with 6.4 mm x 8 mm (1/4 in. x
5/16 in.) long pegs. If a torquing type spanner tool is used to tighten the end cap,
tighten the end cap to the specified torque. Close the cam lever to the up position.

51145

Spanner wrench 91-74951

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
Power Trim and Steering
114 92-802880A1 92-802880Q1
Fluid

Description Nm lb. in. lb. ft.

End cap 61 45
8. Open and close the cam lever, watching for bubbles coming from the accumulator check
ball hole. When the bubbles stop, fill the accumulator opening to the top with fluid.
Grease threads on the accumulator and opening with 2-4-C Marine Lubricant with
Teflon. Start the accumulator in the threads, and open the cam lever (down position).
Tighten the accumulator to the specified torque.

a b

51143

a - Accumulator
b - Cam lever
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

Description Nm lb. in. lb. ft.

Accumulator 47 35

NOTE: If the filling procedure is done correctly, it should be difficult to turn the cylinder rod
assembly by hand.

Page 5C-38 90-883064R02 JULY 2006

 Manual Tilt Assist

Fluid Filling Procedure - Option Two

INSTRUCTIONS FOR MAKING A RETAINING TOOL

5 mm x 7.5 cm
(3/16 in. x 3 in.)
Steel Plate

10 mm x 33 cm
(3/8 in. x 13 in.)
Threaded Rod

10 cm x 6.4 mm
(4 in. x 1/4 in.) minimum
Channel Iron

25 cm
(10 in.)
25 mm 20 cm
(1 in.) (8 in.)

76 mm
(3 in.)

2 holes, 11 mm
(7/16 in.) dia.

12.5 cm 30 mm dia.
(5 in.) (1-1/4 in.)

50.8 cm
(20 in.)

5 cm
(2 in.)

10 cm
(4 in.)

15.2 cm 20.3 cm 2 holes, 10 mm

(6 in.) (8 in.) (3/8 in.) dia.

90-883064R02 JULY 2006 Page 5C-39

Manual Tilt Assist

FILLING AND BLEEDING PROCEDURE

IMPORTANT: While bleeding the tilt system, time must be allowed between each
stroke to allow the air bubbles to dissipate.
1. With the shock rod in the full up position, and the manifold cam lever open facing down,
secure the tilt system to the retaining tool, and container. A No. 10 can, or 1.4 kg (3 lb.)
coffee can could be used.
2. Fill the container to near full level using Power Trim and Steering Fluid. If not available,
use automotive Automatic Transmission Fluid (ATF).
IMPORTANT: The fluid level must remain above the accumulator opening during the
bleeding process.

e b
c
a

d 50447

a - Retaining tool
b - Tilt system
c - Container
d - Cam lever
e - Accumulator opening
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
Power Trim and Steering
114 92-802880A1 92-802880Q1
Fluid

3. Bleed unit by pushing the rod down slowly, 18 - 20 seconds per stroke until stopped at
the base. Wait until all the air bubbles exit accumulator base.

Page 5C-40 90-883064R02 JULY 2006

 Manual Tilt Assist

4. During the up stroke, pull up on the rod slowly 76 mm (3 in.) from the base.
5. Wait until all the air bubbles exit the accumulator base.

50433

6. Slowly cycle the unit 5 - 8 times as described in Steps 3 - 5. Allow all the bubbles to
dissipate before proceeding onto the next cycle.
7. Allow the unit to stand five minutes, then proceed to cycle the unit 2 - 3 more times
using the same procedure. No air bubbles should appear from the accumulator port at
this time.
8. With the oil level well above the accumulator port, slowly pull the rod to the full up position.
9. Install the accumulator making sure the air bubbles do not enter the system.
10. Tighten the accumulator.

50432
50432

90-883064R02 JULY 2006 Page 5C-41

Manual Tilt Assist

11. With the cam lever remaining open facing down, remove the tilt assembly from the oil,
and secure in a soft jawed vise. Tighten the accumulator to the specified torque.

50433

Description Nm lb. in. lb. ft.

Accumulator 47 35

Manual Tilt System Installation

1. Lubricate the lower pivot pin mounting holes with 2-4-C Marine Lubricant with Teflon.
2. Apply 2-4-C Marine Lubricant with Teflon to the lower pivot pin, and start the lower pivot
pin into the pivot pin bore.

95
51148

a - Lower pivot pin

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

Page 5C-42 90-883064R02 JULY 2006

 Manual Tilt Assist

3. Reinstall the manual tilt system, bottom first. Reconnect the release valve link rod.
4. Using a suitable punch, drive the lower pivot pin into the clamp bracket, and trim cylinder
assembly until the pivot pin is flush with the outside surface.

1 51147

51144

a - Lower pivot pin

b - Manual tilt system
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

5. Using a suitable punch, drive the lower trilobe pin into its hole until seated.

a - Trilobe pin

90-883064R02 JULY 2006 Page 5C-43

Manual Tilt Assist

6. Apply 2-4-C Marine Lubricant with Teflon to the surface of the upper pivot pin, pivot pin
hole, and shock rod hole.
7. Using a mallet, drive the upper pivot pin into the swivel bracket, and through the shock
rod until the pivot pin is flush with the swivel bracket.

a
c
e

f
b
d

95

51148

51148

a - Pivot pin
b - Pivot pin bore
c - Shock rod bore
d - Pivot pin
e - Swivel bracket
f - Shock rod
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

8. Drive the upper trilobe pin into its hole until seated.

51147

a - Trilobe pin

Page 5C-44 90-883064R02 JULY 2006

 Manual Tilt Assist

9. Install the sacrificial anode.

a 55465

a - Sacrificial anode

10. Check the manual release cam adjustment. The cam must open, and close freely. Adjust
the link rod as necessary.

Manual Release Valve Adjustment

1. With the outboard in the full up position, place the tilt lock lever forward.
2. Lift the cam lever with the link rod to the full up position.

b
51143

a - Tilt lock lever

b - Cam lever
c - Link rod

3. The link rod end must snap onto the ball of the tilt lock lever without moving the tilt lock
lever, or the cam lever.

90-883064R02 JULY 2006 Page 5C-45

 Non Bigfoot Gear Housing

Lower Unit
Section 6A - Non Bigfoot Gear Housing
1B227000 and Below (Short Models)
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Propeller Shaft Disassembly . . . . . . . . . . . 6A-29
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5 Propeller Shaft and Carrier Inspection . . . . . 6A-30
Gear Housing (Driveshaft) (2:1 Gear Ratio) . . 6A-6 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-30
Gear Housing (Propeller Shaft) Cam Follower . . . . . . . . . . . . . . . . . . . . . . . . 6A-30
(2:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-30
General Service Recommendations . . . . . . . 6A-12 Reverse Gear Bearing . . . . . . . . . . . . . . . . 6A-31
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-12 Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . 6A-32
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-12 Gear Housing Reassembly . . . . . . . . . . . . . . . 6A-36
Draining and Inspecting Gear Lubricant . . . . 6A-13 Shift Shaft Assembly . . . . . . . . . . . . . . . . . . 6A-36
Gear Housing Removal . . . . . . . . . . . . . . . . . . 6A-14 Pinion Bearing Race . . . . . . . . . . . . . . . . . . 6A-37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-38
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16 Pinion Gear/Driveshaft Assembly . . . . . . . 6A-39
Bearing Carrier and Propeller Shaft . . . . . 6A-18 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6A-40
Pinion Gear, Driveshaft, and Forward Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . 6A-42
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-19 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6A-43
Water Pump Seals . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A-22
6A-24
Gear Housing Pressure Test . . . . . . . . . . . . . .
Gear Housing Installation . . . . . . . . . . . . . . . . .
6A-46
6A-47
6
Driveshaft Upper Bearing . . . . . . . . . . . . . . 6A-24 Trim Tab Adjustment and Replacement . . . . 6A-49 A
Pinion Gear Bearing . . . . . . . . . . . . . . . . . . 6A-25 Trim Tab Replacement . . . . . . . . . . . . . . . . 6A-49
Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-25 Trim Tab Adjustment . . . . . . . . . . . . . . . . . . 6A-49
Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-25 Filling Gear Housing with Lubricant . . . . . 6A-50
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-28

90-883064R02 JULY 2006 Page 6A-1

Non Bigfoot Gear Housing

Special Tools
1. Bearing (P/N 31-85560)

54978

2. Driver (P/N 91-13779)

3. Bearing Puller & Installation Tool (P/N 91-31229A7)

a. Nut (P/N 11-24156)

b. Washer (P/N 12-34961) (2)

c. Plate (P/N 91-29310)

d. Shaft (P/N 91-31229)

Page 6A-2 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

4. Bearing Puller Tool (P/N 91-27780)

5. Mandrel (P/N 91-36571T)

6. Universal Puller Plate (P/N 91-37241)

7. Driver Head (P/N 91-37312T)

8. Driver (P/N 91-817011T)

90-883064R02 JULY 2006 Page 6A-3

Non Bigfoot Gear Housing

9. Driver Rod (P/N 91-37323)

10. Driveshaft Holding Tool

a. 4-stroke models (P/N 91-83180M)

11. Mandrel (P/N 91-825197T)

12. Driver (P/N 91-817007T)

13. Mandrel (P/N 91-825198)

14. Pilot (P/N 91-825199)

Page 6A-4 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

15. Spring Hook (P/N 91-825200A1)

16. Driver (P/N 91-826872)

17. Leakage Tester (P/N FT8950)

Specifications
Gear Ratio 2.00:1
Gearcase Capacity 440 ml (14.9 fl. oz.)
Lubricant Type Premium Gear Lubricant
Forward Gear
Number of Teeth 26 Spiral/Bevel
Pinion Gear
Gear Housing Number of Teeth 13 Spiral/Bevel
(2.00:1) Pinion Height 0.64 mm (0.025 in.)
Forward Gear Backlash No adjustment
Water Pressure (Warm Engine)
@ 800 RPM 14 - 28 kPa (2 - 4 psi)
@ 6000 RPM (WOT) 69 - 103 kPa (12 - 17 psi)
Leak Test Pressure 68 - 83 kPa (10 - 12 psi)
for five minutes

90-883064R02 JULY 2006 Page 6A-5

Non Bigfoot Gear Housing

Gear Housing (Driveshaft) (2:1 Gear Ratio)

95

23
24
22
7
7
28
25 95

14
74
27 82 29
12
13 95
30
95

95
15 95 31
26
21 32
33
16 2 35
17
34
18

36
3
95
20 37

38
19

11

5
135 mm/3.44 in. 10 82 4

Torpedo dia. 7
9
7
8 117
6

Page 6A-6 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Gear Housing (Driveshaft) (2:1 Gear Ratio)

Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
– 1 Gear housing (Short)
– 1 Gear housing (Long)
1 1 Gear housing (Basic)
2 1 Seal/Plate kit
3 1 Plate (Part Of Ref #2)
4 1 Screw (0.375-16 x 0.25) 7 60
5 1 Washer - Sealing
6 1 Drain screw 7 60
7 1 Washer - Sealing
8 1 Nut 68 50
9 1 Pinion gear (13 teeth)
10 1 Bearing assembly - Roller
11 1 Cup (Part Of Ref #10)
12 4 Screw (M6 x 16) 7 60
13 1 Water pump assembly
1 Seal - Water tube (Short - 1-3/4)
14
1 Seal - Water tube (Long - 2-1/4)
15 1 Washer
16 1 Key
17 1 Washer
18 1 Gasket
19 1 Gasket (Lower)
20 1 Base plate
21 1 Impeller
22 1 Water pump base assembly
23 1 Seal - Oil
24 1 Seal - Oil
25 1 O-ring
1 Driveshaft (Short)
26
1 Driveshaft (Long)
27 1 Ball bearing
28 1 Cable tie
29 1 Boot - Shift shaft
30 1 Retainer - Shift shaft
31 1 O-ring
32 1 O-ring
33 1 Washer
1 Shift shaft (Short)
34
1 Shift shaft (Long)
35 1 Washer
36 1 Roll pin
37 1 Cam - Shift
38 1 Pin

90-883064R02 JULY 2006 Page 6A-7

Non Bigfoot Gear Housing

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

7 Loctite 271 Threadlocker 92-809819 92-809819

117 Loctite Primer N 92-809824 92-809824

74 Loctite 405 Purchase locally Purchase locally

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

Page 6A-8 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Gear Housing (Driveshaft) (2:1 Gear Ratio)

95

23
24
22
7
7
28
25 95

14
74
27 82 29
12
13 95
30
95

95
15 95 31
26
21 32
33
16 2 35
17
34
18

36
3
95
20 37

38
19

11

5
135 mm/3.44 in. 10 82 4

Torpedo dia. 7
9
7
8 117
6

90-883064R02 JULY 2006 Page 6A-9

Non Bigfoot Gear Housing

Gear Housing (Propeller Shaft) (2:1 Gear Ratio)

135 mm/3.44 in.
42
Torpedo dia.

44 41

46
43
45 67 40 39
55
54 53

1
39
73
52
51
69
70
7 47
50
49
72
82
65 48
64
66 87

68
59
63
71
62 60
61
58
57
82

95
95 56
82
95

95

Page 6A-10 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Gear Housing (Propeller Shaft) (2:1 Gear Ratio)

Torque
Ref
Ref.
No. Qty. Description Nm lb. in. lb. ft.
– 1 Gear housing (Short)
– 1 Gear housing (Long)
1 1 Gear housing (Basic)
39 2 Dowel pin
40 1 Gasket water tube
41 1 Tube
42 1 Plug - rubber
43 1 Screen - Water Inlet
44 1 Trim tab
45 1 Screw (M8 x 20) 21.5 16
46 1 Washer
47 1 Forward gear assembly (26 teeth)
48 1 Roller bearing assembly
49 1 Cup
50 1 Roller bearing
51 1 Follower - Cam
52 1 Spring
53 1 Pin - Cross
54 1 Clutch
55 1 Spring
56 1 Propeller shaft
57 1 Reverse gear (26 teeth)
58 1 Ball bearing
59 1 Bearing carrier
60 1 O-ring
61 1 Needle bearing
62 1 Oil seal
63 1 Oil seal
64 2 Washer
65 2 Screw (M8 x 25 - Cap screw) 22.5 16.5
66 2 Threaded insert
67 1 Decal (2:1)
68 1 Thrust hub
69 1 Prop nut kit These replacement parts 75 55
70 1 Tab washer are not included with
71 4 Screw complete gear housing 54 40
72 4 Washer replacement
73 1 Plug

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

7 Loctite 271 Threadlocker 92-809819 92-809819

High Performance Gear

87 92-802854A1 92-802854Q1
Lubricant

90-883064R02 JULY 2006 Page 6A-11

Non Bigfoot Gear Housing

General Service Recommendations

There may be more than one way to disassemble or reassemble a particular part. Therefore,
it is recommended that the entire procedure be read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
In many cases, disassembly of a sub-assembly may not be necessary until cleaning and
inspection reveals that disassembly is required for replacement of one or more components.
The service procedure order in this section is a normal disassembly, reassembly sequence.
The threaded parts are right hand, unless otherwise indicated.
When holding, pressing, or driving is required, use soft metal vise jaw protectors or wood
for protection of parts. Use a suitable mandrel, one that will contact only the bearing race
when pressing or driving bearings.
Whenever compressed air is used to dry a part, verify that no water is present in the air line.
Bearings
All bearings must be cleaned and inspected. Clean bearings with solvent, and dry with
compressed air. Air should be directed at the bearing so that it passes through the bearing.
Do not spin bearing with compressed air, as this may cause the bearing to score from lack
of lubrication. After cleaning, lubricate bearings with Premium Gear Lubricant. Do not
lubricate the tapered bearing cups until after inspection.

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

Inspect all bearings for roughness, catches, and bearing race side wear. Work inner bearing
race in and out, while holding outer race, to check for side wear. When inspecting tapered
bearings, determine the condition of the rollers, and the inner bearing race by inspecting the
bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles, and/or
discoloration from overheating. Always replace the tapered bearing and race as a set.
Inspect the gear housing for bearing races that have spun in their respective bores. If a race
has spun, the gear housing must be replaced.
Roller bearing condition is determined by inspecting the surface of the shaft that the roller
bearing supports. Check shaft surface for pitting, scoring, grooving, imbedded particles,
uneven wear, and/or discoloration from overheating. The shaft, and bearing must be
replaced if such a condition exists.
Seals
As a normal procedure, all O-rings and oil seals should be replaced without regard to
appearance. To prevent leakage around the seals, apply Loctite 271 Threadlocker to the
outer diameter of all metal case seals. When using Loctite on seals or threads, the surfaces
must be clean and dry. Apply 2-4-C Marine Lubricant with Teflon on all O-rings, and on I.D.
of oil seals. Apply 2-4-C Marine Lubricant with Teflon to the external surfaces of the bearing
carrier.
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

7 Loctite 271 Threadlocker 92-809819 92-809819

Page 6A-12 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Draining and Inspecting Gear Lubricant

WARNING
If a gear housing is installed on an outboard, disconnect and isolate the spark plug
leads from the spark plugs before working near the propeller.

1. With the gear housing in normal running position, place a clean pan under the housing;
remove the vent plug, and fill/drain plug with gaskets.

a - Vent plug/washer
b - Fill/drain plug/washer

2. Inspect the gear lubricant for metal particles. Drain the lubricant into a clean
pan/container. The presence of fine metal particles resembling powder in the gear
lubricant indicates normal wear. The presence of metal chips in the gear lubricant
indicates the need for gear housing disassembly, and component inspection.
3. Note the color of the gear lubricant. White or cream color may indicate presence of water
in the lubricant. Gear lubricant which has been drained from a gearcase recently in
operation will have a yellowish color due to lubricant agitation/aeration. Gear lubricant
which is mixed with assembly lubricant Special Lubricant 101 or 2-4-C Marine Lubricant
with Teflon, will also be creamy white in color. This is normal and should not be confused
with the presence of water. If water is suspected to be present in the gearcase, a
pressure check of the gearcase should be made with no lubricant in the gearcase. The
gearcase should hold 69 to 83 kPa (10 to 12 psi) of pressure for five minutes without
leaking down. Pouring a portion of the gear lubricant into a glass jar, and allowing the
lubricant to settle will allow any water in the lube to separate and settle to the bottom of
the jar.
4. Presence of water in the gear lubricant indicates the need for disassembly and
inspection of oil seals, seal surfaces, O-rings, water pump gaskets, and gear housing
components for damage. If the gearcase is rebuilt, the gearcase should be pressure
checked before filling with lubricant.

90-883064R02 JULY 2006 Page 6A-13

Non Bigfoot Gear Housing

Gear Housing Removal

WARNING
To prevent accidental engine starting, remove and isolate the spark plug leads from
the spark plugs before removing the gear housing.
1. Remove and isolate the spark plug leads from the spark plugs.
2. Shift into neutral.
3. Disconnect the shift shaft by unsnapping the retainer to the lower clip, and sliding the
retainer to the left.

a - Retainer
b - Lower clip

4. Use an indelible marker to scribe a line showing alignment of the trim tab to the
gearcase, and remove the trim tab screw and washer.

52835

a - Trim tab screw and washer

b - Scribe line

Page 6A-14 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

5. Remove the nut and washer in the trim tab cavity.

52835

a - Nut and washer

6. Remove the mounting screws securing the gearcase to the driveshaft housing.

52836

a - Screw (4)

90-883064R02 JULY 2006 Page 6A-15

Non Bigfoot Gear Housing

Disassembly
Water Pump
NOTE: If the water tube seal remained in the driveshaft housing, remove the seal from the
housing, and reinstall on the water pump cover.
1. Remove the screws securing the pump cover.

52830

a - Water tube seal

b - Screw (4)

NOTE: Replace the water pump cover if the thickness of steel at the discharge slots is
1.524 mm (0.060 in.) or less, or if the grooves (other than impeller sealing groove) in the
water pump cover are more than 0.762 mm (0.030 in.) deep.

Page 6A-16 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

2. Remove cover, washer above impeller, impeller, key, and washer below impeller.
3. Remove cover gasket, base plate, and base gasket.

d
e

52692

a - Cover
b - Nylon washer above impeller
c - Impeller
d - Key
e - Nylon washer below impeller
f - Cover gasket
g - Face plate
h - Base gasket

4. Inspect the impeller. Replace impeller if any of the following conditions exist:
• Impeller blades are cracked, torn, or worn.
• Impeller is glazed, or melted.
• Rubber portion of impeller is not bonded to the impeller hub.

90-883064R02 JULY 2006 Page 6A-17

Non Bigfoot Gear Housing

5. Remove and/or replace exhaust deflector plate if damaged.

52832

a - Deflector plate

Bearing Carrier and Propeller Shaft

1. Remove bearing carrier attaching screws, and locking tab washers or flat washers.
Discard the tab washers.

a - Screw, tab washer or flat washer (2 each)

b - Tab washer (2) Style 2

2. Use a puller to remove the carrier assembly from the gearcase.

52829

a - Puller
Bearing Puller Tool 91-27780

Page 6A-18 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

NOTE: When removing the propeller shaft assembly, the cam follower may dislodge.
Retrieve the cam follower from the gear housing.
3. Remove the propeller shaft assembly.

a
52864

a - Propeller shaft

Pinion Gear, Driveshaft, and Forward Gear

1. Install the driveshaft holding tool onto the driveshaft splines.
2. Remove the pinion nut.

c a

52864

a - Driveshaft holding tool

b - Pinion nut
c - Pinion gear
Driveshaft Holding Tool 91-83180M

90-883064R02 JULY 2006 Page 6A-19

Non Bigfoot Gear Housing

3. Remove the driveshaft assembly and the pinion gear.

4. Remove the forward gear.

52870

a - Forward gear

5. The shift shaft assembly is held in place by the water pump. Remove the shift shaft
assembly with a quick upward pull.

52841

a - Shift shaft assembly

Page 6A-20 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

6. Insert the pinion bearing race puller through the gearcase, and position inside of the
pinion bearing race. Insert the driver into the puller through the driveshaft cavity, and
drive out race.

52844

a - Puller
b - Driver
Pinion Bearing Race Puller 91-825200A1
Driver 91-13779

7. Remove the forward bearing race with the puller.

b
a

53838

a - Race
b - Puller
Bearing Puller Tool 91-27780

90-883064R02 JULY 2006 Page 6A-21

Non Bigfoot Gear Housing

Water Pump Seals

NOTE: All gaskets, seals, and O-rings should be replaced as a normal repair procedure
during the gearcase disassembly.
NOTE: Do not use a screwdriver to remove the seals from the carrier, as the carrier may
be damaged.
1. Using a suitable mandrel, press both seals from the carrier.

a - Neoprene ribbed seal

b - Metal cased seal
c - Carrier
d - O-ring

2. Apply Loctite 271 Threadlocker to the O.D. of the metal cased seal. With the seal lip
facing away from the large shoulder of the mandrel, press the seal into the carrier until
the mandrel bottoms on the carrier.

b a 7

a - Metal cased seal - lip facing down

b - Mandrel
Mandrel 91-825197T

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

Page 6A-22 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

3. With the lip of the ribbed neoprene O.D. seal facing towards the small shoulder of the
mandrel, press the seal into the carrier until the mandrel bottoms on the carrier.

b
a

52853

a - Ribbed neoprene seal - lip facing up

b - Mandrel
Mandrel 91-825197T

4. Install a new O-ring on the carrier. Apply a light coat of 2-4-C Marine Lubricant with Teflon
to the new O-ring. Apply a liberal amount of grease on the new seal lips.
b

95

52825

a - O-ring
b - Seals
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

90-883064R02 JULY 2006 Page 6A-23

Non Bigfoot Gear Housing

Inspection
Driveshaft Upper Bearing
1. Inspect the bearing for rust, roughness, or discoloration from lack of lubricant.
2. Do not remove the bearing from the driveshaft unless the bearing must be replaced, as
the removal process will damage the bearing.
3. If the bearing must be replaced, position the driveshaft assembly in a vise, jaws of vise
supporting only the bearing, and strike the top of the driveshaft with a lead hammer while
holding the driveshaft.

a - Bearing

4. To install the new bearing, thread the old pinion nut 3/4 way onto the driveshaft. Position
the universal puller plate under the bearing, and press on pinion nut while holding the
driveshaft until bearing seats against the shoulder.

b
c

52387

a - Old pinion nut

b - Bearing
c - Universal puller plate
Universal Puller Plate 91-37241

Page 6A-24 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Pinion Gear Bearing

1. Inspect the bearing for rust, roughness, or discoloration from lack of lubricant.
2. If the bearing is damaged, bearing and race must be replaced as an assembly.
3. If the race appears to have spun in the driveshaft bore, the gearcase housing must be
replaced.

b
52823

a - Bearing
b - Race

Pinion Gear
1. Inspect pinion gear teeth for rust, chipping, teeth that have sharp edges, and signs of
teeth breaking.
2. If pinion gear teeth are damaged, inspect forward and reverse gear teeth for damage.
3. Replace gears as required.

52839

Forward Gear
1. Inspect forward gear teeth for rust, chipping, teeth that have sharp edges, or broken
teeth.
2. Inspect forward gear clutch jaws for wear. Rounded jaws indicate the following:
• Improper shift cable adjustment.
• Engine idle speed too high.
• Shifting too slowly.

52874

90-883064R02 JULY 2006 Page 6A-25

Non Bigfoot Gear Housing

3. Inspect propeller shaft forward gear bearing surface to determine the condition of the
forward gear needle bearing. If bearing surface is discolored from lack of lubricant, pitted
or worn, propeller shaft and bearing should be replaced.

52846 52874

a - Bearing surface
b - Bearing

4. Use a suitable mandrel to press the needle bearing out of the forward gear.

a b

52873

a - Mandrel
b - Bearing

5. Use a driver to press the new needle bearing into the forward gear. Press on the
numbered side of the bearing. Apply gear lubricant to bearing before pressing into gear.

82 b

52847

a - Driver
b - Bearing
Driver 91-826872

Page 6A-26 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

6. Inspect forward gear tapered bearing and race for rust, roughness, or excessive wear.
7. If the bearing is in serviceable condition, do not remove bearing from gear, as the
removal process will damage the bearing.
8. If the bearing must be replaced, remove bearing from gear using the universal puller
plate and suitable mandrel.

a - Universal puller plate

b - Mandrel
Universal Puller Plate 91-37241

9. Replace the bearing and race as a set. Use suitable mandrel to press the bearing onto
the gear. Press only on the inner race when installing the bearing.

a - Mandrel

90-883064R02 JULY 2006 Page 6A-27

Non Bigfoot Gear Housing

Shift Shaft
1. Inspect the shift cam for wear or galling. Replace the cam if necessary.
2. If the cam is worn, inspect the cam follower in the end of the propeller shaft for wear.

a
52845

a - Shift cam
b - Cam follower

3. Inspect the shift shaft boot for deterioration.

4. Inspect the shift shaft carrier O-ring for cuts or abrasions. It is a good service procedure
to replace all O-rings, seals, and gaskets regardless of appearance.

52828

a - Boot
b - O-ring

Page 6A-28 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Propeller Shaft Disassembly

1. Remove the propeller shaft from the carrier, and disassemble the shaft.

d
a c
b

e f

a - Propeller shaft
b - Retaining spring
c - Clutch dog
d - Cross pin
e - Cam follower spring
f - Cam follower

2. Remove the reverse gear and bearing from the carrier with puller tool.
b

52840

a - Reverse gear and bearing

b - Bearing puller tool
Bearing Puller Tool 91-27780

90-883064R02 JULY 2006 Page 6A-29

Non Bigfoot Gear Housing

Propeller Shaft and Carrier Inspection

Clutch
1. Inspect the clutch jaws for chips or rounding off.
2. If wear is present, inspect corresponding forward or reverse gear matching jaws for
similar wear. Replace appropriate components as required.

52824

Cam Follower
1. Inspect the cam follower for wear or galling.
2. If wear is present, inspect corresponding shift cam for wear. Replace if worn.

52822

Reverse Gear
1. Inspect the reverse gear teeth for rust, chipping, teeth that have sharp edges, or broken
teeth.
2. Inspect the reverse gear clutch jaws for wear. Rounded jaws indicate the following:
• Improper shift cable adjustment.
• Engine idle speed too high.
• Shifting too slowly.

52875

Page 6A-30 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Reverse Gear Bearing

1. Inspect the bearing for rust, roughness, or excessive wear.
2. If the bearing is in serviceable condition, do not remove the bearing from the gear as the
removal will damage the bearing.
3. If the bearing must be replaced, remove the bearing from the gear using a universal
puller plate and driver.

a
c
b

a - Bearing
b - Reverse ear
c - Universal puller plate
d - Driver
Universal Puller Plate 91-37241
Driver 91-3731T

4. Apply gear lubricant to the I.D. of the bearing. Install a new bearing using a suitable
mandrel. Press on only on the inner race when installing the bearing.

b
82

52867

a - Mandrel
b - Bearing
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

90-883064R02 JULY 2006 Page 6A-31

Non Bigfoot Gear Housing

Bearing Carrier
Needle Bearing
1. The condition of the carrier needle bearing can be determined by inspecting its running
surface on the propeller shaft.
2. If the shaft is discolored from lack of oil, or pitted, replace the bearing and shaft.
3. The bearing can be removed by using a driver rod and driver. Removing the bearing will
also remove both propeller shaft seals.

51264
d
a - Driver rod
b - Driver
c - Needle bearing
d - Seals
Driver rod 91-37323
Driver 91-37312T

4. Apply gear lubricant to the O.D. of the bearing.

5. Install the bearing with mandrel.
6. Press the bearing into the carrier until the needle bearing installer bottoms on the carrier.

82 a

52861

a - Bearing
b - Needle bearing installer
Needle Bearing Installer 91-817011T

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

Page 6A-32 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

7. Apply Loctite 271 Threadlocker to the O.D. of the small diameter seal.
8. With the seal lip facing away from the large shoulder of the mandrel, press the seal into the
carrier until the bearing carrier seal installer bottoms on the carrier.

52862

a - Seal
b - Bearing carrier seal installer
Bearing Carrier Seal Installer 91-817007T

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

9. Apply Loctite 271 Threadlocker to the O.D. of the large diameter seal.
10. With the seal lip facing towards the small shoulder of the mandrel, press the seal into
the carrier until the bearing carrier seal installer bottoms on the carrier.

a
7

52863

a - Seal
b - Bearing carrier seal installer
Bearing Carrier Seal Installer 91-817007T

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

90-883064R02 JULY 2006 Page 6A-33

Non Bigfoot Gear Housing

NOTE: If service tools are not available, the following reference dimensions apply for
installing bearing and seals to proper depths.
20 mm (0.82 in.)

a 51275

a - Bearing

11 mm (0.44 in.)
1 mm (0.04 in.)

b
a

51275
a - Oil seal - install with lip down
b - Oil seal install with lip up

Page 6A-34 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

11. The bearing carrier O-ring should be inspected for cuts and abrasions.
NOTE: It is a good repair procedure to replace all O-rings and seals regardless of appear-
ance.
12. Apply 2-4-C Marine Lubricant with Teflon to the O.D. of the bearing carrier and also to
the O-ring. Install the O-ring onto the bearing carrier.
13. Using a suitable mandrel, press the reverse gear assembly into the carrier.

b
c
95 a

52827

a - O-ring
b - Mandrel
c - Reverse gear assembly
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

90-883064R02 JULY 2006 Page 6A-35

Non Bigfoot Gear Housing

Gear Housing Reassembly

IMPORTANT: This gearcase assembly does not need shim for the gear assemblies.
Backlash cannot be adjusted. The mechanic must verify that all bearing races are
firmly seated in the gearcase during reassembly and that all gearcase components
are in serviceable condition. Prior to installing the seal carrier and water pump
assembly on the driveshaft, the forward gear should be held stationary with a
screwdriver or similar tool, while pulling up on the driveshaft. Lightly turn the shaft
back and forth. A light clicking sound should be heard indicating the presence of
backlash between the forward gear and the pinion gear. If this backlash is not
present, the pinion gear race and/or forward gear race are not fully seated. The races
should be removed and inspected for debris. Reinstall the races and check backlash.
If backlash is still not present, replace gear housing.
Shift Shaft Assembly
1. Apply 2-4-C Marine Lubricant with Teflon to the new O-rings, and install the O-rings on
the shift shaft and carrier.
2. Install the carrier on the shift shaft.
IMPORTANT: When installing shift shaft assembly into gear housing, do not bottom
out shaft in housing. Pull up on shift shaft until shift boot is not deformed. If shaft is
bottomed out, cross pin in clutch dog will be bent by cam follower when tightening
carrier bolts.
3. Install the shift shaft/carrier assembly into the gear housing.
4. Secure boot to the carrier with cable tie.
5. Position the shift shaft so the ramp faces towards the propeller shaft.

d c
a 95

e
52841

a - O-rings
b - Carrier
c - Boot
d - Cable tie
e - Ramp
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

Page 6A-36 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Pinion Bearing Race

1. Apply Premium Gear Lubricant to the O.D. of the race.
2. Position the race in the gear housing, numbers up - taper side facing down.
3. Draw the race up into the housing until seated.
a f
b c
d

82

52842

a - Threaded rod
b - Washer (2)
c - Bearing
d - Plate
e - Pilot
f - Nut
g - Mandrel
Shaft 91-31229
Washer (2) 12-34961
Bearing 31-85560
Plate 91-29310
Pilot 91-825199
Nut 11-24156
Mandrel 91-825198

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

90-883064R02 JULY 2006 Page 6A-37

Non Bigfoot Gear Housing

Forward Gear
1. Apply Premium Gear Lubricant to the O.D. of the race. Install forward gear bearing race
into the housing using the mandrel and propeller shaft. Use a lead hammer on the
propeller shaft to prevent damage to the threads. The bearing carrier should be installed
to keep the propeller shaft centered while seating the race.

82 52843

a - Race
b - Mandrel
Mandrel 91-36571T

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

NOTE: Remove drain plug/magnet assembly from the gearcase if installed, to prevent
possible breakage of the magnet if struck by the forward gear.
2. Install the forward gear and bearing assembly into the forward gear race.

52870

a - Forward gear assembly

Page 6A-38 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Pinion Gear/Driveshaft Assembly

1. Clean the driveshaft, and pinion nut threads with Loctite Primer or suitable degreaser.
2. Position the pinion bearing into the race while installing the driveshaft, and pinion gear
into the housing.
3. Apply Loctite 271 Threadlocker to the pinion nut threads.
4. Install new pinion nut, with recessed shoulder toward the pinion gear.
5. Using the driveshaft holding tool to hold the driveshaft, tighten the pinion nut to the
specified torque.

a
7

52864

a - Pinion nut
b - Pinion gear
c - Pinion bearing
d - Driveshaft holding tool
Driveshaft Holding Tool 91-83180M

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

117 Loctite Primer N 92-809824 92-809824

Description Nm lb. in. lb. ft.

Pinion nut 67.8 50

90-883064R02 JULY 2006 Page 6A-39

Non Bigfoot Gear Housing

Propeller Shaft
1. Slide clutch over propeller shaft with the short shoulder facing towards forward gear.
Align cross pin hole with slot in propeller shaft.
2. Insert the cam follower spring into the propeller shaft.

a d
b c

e f

a - Propeller shaft
b - Retaining spring
c - Clutch dog
d - Cross pin
e - Cam follower spring
f - Cam follower

3. Compress the follower spring enough to insert the cross pin partially through the clutch.
4. Remove the wrench and press the cross pin through the clutch and propeller shaft until
flush.
c a

52851
b
a - Short shoulder
b - Allen wrench
c - Cross pin

5. Install the spring. Do not allow the spring coils to overlap each other.
a

a - Spring

Page 6A-40 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

NOTE: Apply 2-4-C Marine Lubricant with Teflon to the cam follower before installation into
the propeller shaft. This will prevent the cam follower from falling out during installation of
the propeller shaft assembly.
6. Install the cam follower.

95

52826

a - Cam follower
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

7. Install the propeller shaft assembly into the gearcase.

a 52864

a - Propeller shaft assembly

90-883064R02 JULY 2006 Page 6A-41

Non Bigfoot Gear Housing

Bearing Carrier
1. Install the carrier into the gearcase.
2. Discard the original tab washers or the thin 1.60 mm (0.063 in.) flat washers, and the
25 mm long screws on the models listed. Install thicker flat washers, and longer screws.
25 (2 Cylinder - 4-Stroke)
USA . . . . . . . 0G621670 and below
45/50 (4 Cylinder - 4-Stroke) Non Bigfoot
USA . . . . . . . 0G621709 and below
30/40 (2 Cylinder - 2-Stroke)
USA . . . . . . . 0G650736 and below
Belgium . . . . NA
40/50 (3 Cylinder - 2-Stroke)
USA . . . . . . . 0G650699 and below
Belgium . . . . NA
Force 40/50 (2 Cylinder - 2-Stroke)
USA . . . . . . . 0E323508 and below
a b c

a - Screw 25 mm long - discard

b - Tab washer - discard
c - Thin flat washer 1.60 mm (0.063 in.) - discard

3. Install thicker flat washers and longer screws.

a b

a - Screw (10-855940-30) 30 mm (1.18 in.) long

b - Washer (12-855941) 2.29 mm (0.090 in.) thick

Page 6A-42 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

4. Tighten the screws to the specified torque.

7 a

a - Screw (2)
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

Description Nm lb. in. lb. ft.

Bearing carrier screw 25 18.4

Water Pump
1. Apply 2-4-C Marine Lubricant with Teflon to the seal carrier O-ring, and seal lips. Install
the seal carrier.
2. Install the exhaust deflector plate.

95
b
a

52832

a - Seal carrier
b - Exhaust deflector
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

90-883064R02 JULY 2006 Page 6A-43

Non Bigfoot Gear Housing

3. Install the base gasket, base plate, pump cover gasket with the neoprene strip up, nylon
washer, and impeller key.

d
c

f
e

a
52868

a - Base gasket
b - Base plate
c - Cover gasket
d - Neoprene strip
e - Nylon washer
f - Key

4. Install the impeller, and nylon washer.

b
a

52869

a - Impeller
b - Nylon washer

Page 6A-44 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

5. Lubricate the I.D. of the impeller housing with 2-4-C Marine Lubricant with Teflon.
6. Rotate the driveshaft clockwise while pushing the impeller housing cover down over the
impeller.
7. Apply Loctite 271 Threadlocker to bottom threads of the screws. Install the screws and
tighten to the specified torque.

b 7

a
52830

a - Cover
b - Screw (4)
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

7 Loctite 271 Threadlocker 92-809819 92-809819

Description Nm lb. in. lb. ft.

Bearing carrier screw 7 60

90-883064R02 JULY 2006 Page 6A-45

Non Bigfoot Gear Housing

Gear Housing Pressure Test

1. Remove the vent plug, and install the pressure test gauge. Tighten securely.

2. Pressurize housing to 69 - 83 kPa (10 - 12 psi), and observe the gauge for five minutes.
3. Rotate the driveshaft, propeller shaft, and move the shift rod while housing is
pressurized to check for leaks.

Gear housing pressure test

Applied air pressure 69 - 83 kPa (10 - 12 psi)
Length of time Five minutes

4. If pressure drop is noted, immerse the housing in water.

5. Re-pressurize to 69 - 83 kPa (10 - 12 psi), and check for air bubbles.
6. Replace the leaking seals as necessary. Retest the housing.
7. Remove the tester from the housing, and install the vent plug.

Page 6A-46 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Gear Housing Installation

WARNING
Disconnect and isolate the spark plug leads before installing the gear housing onto
the driveshaft housing.
1. Position the shift lever in neutral gear position.
2. Tilt engine to the full up position. Engage the tilt lock lever.
3. Shift the gear housing into neutral. The propeller shaft will rotate freely in either direction.

CAUTION
Do not lubricate the top of the driveshaft. Excess lubricant will not allow the
driveshaft to fully engage the crankshaft. Tightening the gear housing fasteners
with excess lubricant on top of the driveshaft will pre-load the driveshaft/crankshaft
and may damage either the powerhead, and gear housing, or both. Wipe the top of
the driveshaft free of lubricant.
4. Lightly apply 2-4-C Marine Lubricant with Teflon onto the driveshaft splines.
5. Position the driveshaft into the driveshaft housing. Move the gear housing upwards in
the driveshaft housing while aligning both shift shafts, water tube seal, and driveshaft
splines.
NOTE: If the driveshaft splines will not align with the crankshaft splines, rotate the flywheel
slightly while pushing the gear housing into the driveshaft housing.
6. Install four screws and washers, two each side. Tighten the screws to the specified
torque.

52836

a - Screw and washers - 2 each side

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

Description Nm lb. in. lb. ft.

Gear housing screw 54 40

90-883064R02 JULY 2006 Page 6A-47

Non Bigfoot Gear Housing

7. Connect the shift shaft by sliding the retainer to the right, and snapping into the upper locked
position.

53859

a - Retainer
b - Clip

8. Install the locknut and washer. Torque the nut to the specified torque.

52833

a - Locknut and washer

Description Nm lb. in. lb. ft.
Locknut 54 40

9. Check shift operation.

a. In neutral, propeller shaft should turn freely in either direction.
b. In forward, propeller shaft should not turn counterclockwise.
c. In reverse, propeller shaft should not turn in either direction.
IMPORTANT: If shift operation is not as described, remove the gear housing, and
correct the shift operation.

Page 6A-48 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Trim Tab Adjustment and Replacement

IMPORTANT: The trim tab is made of a special alloy to aid in protecting the driveshaft
housing and gear housing from galvanic corrosion. Do not paint or place protective
coating on the trim tab, or trim tab corrosion protection function will be lost.
Trim Tab Replacement
Replace the trim tab if damaged, or 50% or more is corroded. Mark the location of the old
trim tab on the anti-ventilation plate before removal, and install a new trim tab in the same
location.
Trim Tab Adjustment
NOTE: The trim tab provides a means to balance some of the steering load that is caused
by propeller torque at higher operating speeds.
NOTE: Loosen the trim tab screw sufficiently to allow the trim tab to disengage from the
locking ridges in the gearcase before attempting to move the tab. Do not strike the trim tab
with a hard object to make adjustments.
1. Shift the engine control into neutral, and turn the ignition key to the “OFF” position.
2. If at higher speeds the boat turns more easily to the left, loosen the screw; move the trim
tab trailing edge to the left when viewed from behind. Tighten the retaining screw to the
specified torque.
3. If the boat turns more easily to the right, loosen the screw; move the trim tab trailing edge
to the right when viewed from behind. Tighten the retaining screw to the specified torque.
a

b
c

52835

a - Trim tab
b - Anti-ventilation plate
c - Trim tab screw and washer
Description Nm lb. in. lb. ft.
Trim tab screw 21 16

90-883064R02 JULY 2006 Page 6A-49

Non Bigfoot Gear Housing

Filling Gear Housing with Lubricant

NOTE: Gear housing lubricant capacity is approximately 440 ml (14.9 fl oz).

WARNING
If a gear housing is installed on an outboard, disconnect and isolate the spark plug
leads from the spark plugs before working near the propeller.

CAUTION
Do not use automotive grease in the gear housing. Use only Premium Gear
Lubricant.
1. Remove any gasket material from the fill and vent plugs, and gear housing. Install new
gaskets on the fill and vent plugs.
IMPORTANT: Never add lubricant without removing the vent plug. The gear housing
cannot be filled because of trapped air. Fill the gear housing when the driveshaft is
in a vertical position.
2. Remove the fill plug and gasket.
3. Insert lubricant tube in the fill hole, then remove vent plug and gasket.
4. Fill until excess lubricant flows out of the vent hole.
5. Replace this vent plug and gasket.
6. Install fill plug and gasket.

a - Vent plug
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

7. Tighten the fill and vent screws to the specified torque.

Description Nm lb. in. lb. ft.

Fill and vent screw 6 55

Page 6A-50 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Lower Unit
Section 6B - Non Bigfoot Gear Housing
1B227000 and Above (Long Models)
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6B-28
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-6 Forward Gear Bearing Race . . . . . . . . . . . 6B-30
Gear Housing (Driveshaft - 2:1) . . . . . . . . . . . 6B-8 Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . 6B-30
Gear Housing (Propeller Shaft - 2:1) . . . . . . . 6B-10 Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . 6B-33
General Service Recommendations . . . . . . . 6B-12 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6B-34
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-12 Lower Driveshaft Bearing Installation . . . 6B-35
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-12 Upper Driveshaft Bearing Installation . . . 6B-36
Draining and Inspecting Gear Lubricant . . . . 6B-13 Forward Gear, Pinion Gear and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-14 Driveshaft Assembly Installation . . . . . . . 6B-37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-15 Pinion Gear Location and
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6B-15 Forward Gear Backlash . . . . . . . . . . . . . . 6B-38
Bearing Carrier and Propeller Shaft . . . . . 6B-17 Determining Pinion Gear Location . . . . . . 6B-38
Propeller Shaft Disassembly . . . . . . . . . . . 6B-20 Determining Forward Gear Backlash . . . . 6B-41
Pinion Gear, Driveshaft and Forward Bearing Carrier and
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Driveshaft Bearing . . . . . . . . . . . . . .
6B-22
6B-23
Propeller Shaft Installation . . . . . . . . . . . .
Water Pump Reassembly/Installation . . .
6B-43
6B-44 6
Lower Driveshaft Bearing . . . . . . . . . . . . . . 6B-24 Gear Housing Pressure Test . . . . . . . . . . . . . . 6B-49
Forward Gear Bearing Race . . . . . . . . . . . 6B-24 Gear Housing Installation . . . . . . . . . . . . . . . . . 6B-51 B
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-25 Filling Gear Housing with Lubricant . . . . . . . . 6B-53
Gear Housing Reassembly . . . . . . . . . . . . . . . 6B-27 Trim Tab Adjustment and Replacement . . . . 6B-54
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-27

90-883064R02 JULY 2006 Page 6B-1

Non Bigfoot Gear Housing

Special Tools

1. Bearing Preload Tool (P/N 91-14311A04)

2. Backlash Indicator Tool (P/N 91-19660--1)

19660-1

3. Bearing Puller Tool (P/N 91-27780)

Page 6B-2 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

4. Universal Puller Plate (P/N 91-37241)

5. Driver Head (P/N 91-37312T)

6. Driver Rod (P/N 91-37323)

7. Bearing Retaining Tool (P/N 91-43506T)

8. Puller Jaws (P/N 91-46086A1)

9. Dial Indicator (P/N 91-58222A1)

90-883064R02 JULY 2006 Page 6B-3

Non Bigfoot Gear Housing

10. Dial Indicator Adapter Kit (P/N 91-83155)

11. Puller Bolt (P/N 91-85716)

12. Forward Gear Bearing Installer (P/N 91-817005)

13. Water Pump Base Seal Installer (P/N 91-817006)

14. Bearing Carrier Seal Installer (P/N 91-817007T)

15. Pinion Gear Location Tool (P/N 91-817008A2)

Page 6B-4 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

16. Forward Gear Bearing Race Driver Cup (P/N 91-817009T)

17. Needle Bearing Installer (P/N 91-817011T)

18. Backlash Indicator Tool (P/N 91-817057A02)

c d
a

51043

Ref. Description Qty.

a Plate 1
b Nut 1
c Stud 1
d Sleeve 1

91-817057A-1 Update Kit (Converts 91-14311A-1 Bearing Preload Kit Tool to a 91-14311A-2)

90-883064R02 JULY 2006 Page 6B-5

Non Bigfoot Gear Housing

19. Lower Driveshaft Bearing Driver Assembly (P/N 91-817058A1)

20. Driveshaft Holding Tool (P/N 91-817070) 55/60 (2-Stroke)

21. Driveshaft Holding Tool (P/N 91-877840A1) 50/60 (4-Stroke)

Page 6B-6 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Specifications
Gear Ratio 2:1
Gearcase Capacity 340 ml (11.5 fl. oz.)
Lubricant Type Premium Gear Lubricant
Forward Gear
Number of Teeth 22 Spiral/Bevel
Pinion Gear
Number of Teeth 12 Spiral/Bevel
Pinion Height 0.64 mm (0.025 in.)
Gear Housing
Pinion Gear Locating Tool 91-817008A2
(2:1)
Forward Gear Backlash 0.28 - 0.43 mm (0.011 - 0.017 in.)
Backlash Indicator Tool 91-19660--1
Mark Number #4 or 9.3 mm (0.366 in.)
Water Pressure (Warm Engine)
@ 800 RPM 7 - 21 kPa (1 - 3 psi)
@ 6000 RPM (WOT) 83 - 172 kPa (12 - 25 psi)
Leak Test Pressure 68 - 83 kPa (10 - 12 psi)
for five minutes

90-883064R02 JULY 2006 Page 6B-7

Non Bigfoot Gear Housing

Gear Housing (Driveshaft) (2:1 Gear Ratio)

95
7 87.37 mm/3.44 in.
36
34
Torpedo dia.
30 22

28 21
95
27 29 20
95 19
32 29
34
95
33

31
7

23
95 18
24

26 7

25

95 10
82 95
6
7
7
17
7 9
15
8 16
5

1 14 95
4
3
35
13
11
12

3 4

7
4
2

Page 6B-8 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Gear Housing (Driveshaft) (2:1 Gear Ratio)

Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
1 1 Gear housing
2 1 Drain screw 6.5 58
3 2 Screw 6.5 58
4 3 Washer - Sealing
5 1 Dowel pin
6 1 Dowel pin
7 1 Pipe plug
8 1 Roller bearing
9 1 Seal kit
10 1 Filler plate
11 1 Pinion gear (13 teeth)
12 1 Nut 67.8 50
13 1 Shift shaft assembly
14 1 Retaining ring
15 1 Bushing assembly
16 1 O-ring
17 1 Oil seal
18 1 Driveshaft
19 AR Shim set (Sizes 006 through 038)
20 1 Tapered roller bearing
21 1 Cup
22 1 Nut 101.7 75
23 1 Water pump base
24 1 O-ring
25 1 Oil seal
26 1 Oil seal
27 1 Impeller
28 1 Key
29 2 Washer
30 1 Water pump
31 1 Gasket (Lower)
32 1 Gasket (Upper)
33 1 Face plate
34 6 Screw (M6 x 16) 6.8 60
35 1 Shift cam
36 1 Coupler

Tube Ref. Description Mercury Part Number Quicksilver Part Number

No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

7 Loctite 271 Threadlocker 92-809819 92-809819

90-883064R02 JULY 2006 Page 6B-9

Non Bigfoot Gear Housing

Gear Housing (Propeller Shaft) (2:1 Gear Ratio)

87.37 mm/3.44 in.
Torpedo dia.

59

65
61
60

1
95 95

63 46
45
64 47
43
42 66
7 40
41 67
56 38
57
58 39
37

62
55
54
95 53 7

51
95

95 52
50
49

94 48

44

Page 6B-10 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Gear Housing (Propeller Shaft) (2:1 Gear Ratio)

Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
1 1 Gear housing
37 AR Shim set (Sizes 006 through 048)
38 1 Tapered roller bearing
39 1 Cup
40 1 Forward gear (26 teeth)
41 1 Roller bearing
42 1 Cam follower
43 1 Slide
44 1 Spring
45 1 Clutch
46 1 Cross pin
47 1 Spring
48 1 Propeller shaft
49 1 Reverse gear (26 teeth)
50 1 Ball bearing
51 1 Bearing carrier assembly
52 1 O-ring
53 1 Roller bearing
54 1 Oil seal
55 1 Oil seal
56 2 Screw (M8 x 30) 25.5 18.8
57 2 Washer
58 2 Threaded insert
59 1 Trim tab
60 1 Screw (M10 x 30) 21.0 186
61 1 Washer
62 1 Thrust hub
63 1 Propeller nut 74.6 55
64 1 Tab washer
65 1 Decal - Gear Ratio
66 4 Washer
67 4 Screw (M10 x 45) 54 40

Tube Ref. Description Mercury Part Number Quicksilver Part Number

No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

7 Loctite 271 Threadlocker 92-809819 92-809819

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

90-883064R02 JULY 2006 Page 6B-11

Non Bigfoot Gear Housing

General Service Recommendations

There may be more than one way to disassemble or reassemble a particular part. Therefore,
it is recommended that the entire procedure be read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
In many cases, disassembly of a sub-assembly may not be necessary until cleaning and
inspection reveals that disassembly is required for replacement of one or more components.
The service procedure order in this section is a normal disassembly, reassembly sequence.
The threaded parts are right hand, unless otherwise indicated.
When holding, pressing, or driving is required, use soft metal vise jaw protectors or wood
for protection of parts. Use a suitable mandrel, one that will contact only the bearing race
when pressing or driving bearings.
Whenever compressed air is used to dry a part, verify that no water is present in the air line.
Bearings
WARNING
To avoid personal injury, wear eye protection and regulate air pressure to not more
than 172 kPa (25 psi) when drying bearings with compressed air. Do not spin bearings
with compressed air as this may cause bearings to score from lack of lubrication.
All bearings must be cleaned and inspected. Clean bearings with solvent, and dry with
compressed air. Air should be directed at the bearing so that it passes through the bearing.
Do not spin bearing with compressed air (see above warning). After cleaning, lubricate
bearings with Premium Gear Lubricant. Do not lubricate the tapered bearing cups until after
inspection.
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

Inspect all bearings for roughness, catches, and bearing race side wear. Work inner bearing
race in-and-out, while holding outer race, to check for side wear. When inspecting tapered
bearings, determine the condition of the rollers, and the inner bearing race by inspecting the
bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles, and/or
discoloration from overheating. Always replace the tapered bearing and race as a set.
Inspect the gear housing for bearing races that have spun in their respective bores. If races
have spun, gear housing must be replaced.
Roller bearing condition is determined by inspecting the surface of the shaft that the roller
bearing supports. Check shaft surface for pitting scoring, grooving, imbedded particles,
uneven wear, and/or discoloration from overheating. The shaft, and bearing must be
replaced if such a condition exists.
Seals
As a normal procedure, all O-rings and oil seals should be replaced without regard to
appearance. To prevent leakage around the seals, apply Loctite 271 Threadlocker to the
outer diameter of all metal case seals. When using Loctite on seals or threads, the surfaces
must be clean and dry. Apply 2-4-C Marine Lubricant with Teflon on all O-rings, and on the
inside diameter of the oil seals. Apply 2-4-C Marine Lubricant with Teflon to the external
surfaces of the bearing carrier.
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

7 Loctite 271 Threadlocker 92-809819 92-809819

Page 6B-12 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Draining and Inspecting Gear Lubricant

WARNING
If a gear housing is installed on an outboard, to avoid accidental starting,
disconnect and isolate the spark plug leads from the spark plugs before working
near the propeller.
1. With the gear housing in normal running position, place a clean pan under the housing;
remove the two vent screws, and one fill/drain screw with gaskets.

b
53922

a - Vent plug
b - Fill/drain plug

2. Inspect the gear lubricant for metal particles (lubricant will have a metal flake
appearance). The presence of fine metal particles resembling powder in the drain pan
indicates normal wear. The presence of metal chips in the drain pan indicates the need
for gear housing disassembly, and component inspection.
3. Note the color of the gear lubricant. White or cream color may indicate presence of water
in the lubricant. Gear lubricant which has been drained from a gearcase recently in
operation will have a yellowish color due to lubricant agitation/aeration. Gear lubricant
which is mixed with assembly lubricant Special Lubricant 101 or 2-4-C Marine Lubricant
with Teflon will also be creamy white in color. This is normal and should not be confused
with the presence of water. If water is suspected to be present in the gearcase, a
pressure check of the gearcase should be made with no lubricant in the gearcase. The
gearcase should hold 69 - 83 kPa (10 - 12 psi) of pressure for five minutes without
leaking down. Pouring a portion of the gear lubricant into a glass jar, and allowing the
lubricant to settle will allow any water in the lubricant to separate, and settle to the bottom
of the jar.
4. Presence of water in the gear lubricant indicates the need for disassembly, and
inspection of oil seals, seal surfaces, O-rings, water pump gaskets, bearings and
bearing surfaces, as well as gear housing components. If the gearcase is rebuilt, the
gearcase should be pressure checked before filling with lubricant.

90-883064R02 JULY 2006 Page 6B-13

Non Bigfoot Gear Housing

Removal
WARNING
To prevent accidental engine starting, remove and isolate the spark plug leads from
the spark plugs before removing the gear housing.
1. Remove and isolate the spark plug leads from the spark plugs.
2. Shift the engine into forward gear.
3. Tilt the engine to full up position.
4. Remove four bolts and washers, two from each side.
5. Remove the trim tab.
6. Remove the locknut and washer in the trim tab recess.
7. Remove the gear housing.

a c

53992

a - Trim tab
b - Locknut and washer
c - Bolts (4) M10 x 45 and washers (4)

Page 6B-14 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Disassembly
Water Pump
NOTE: If the water tube seal remained on the water tube inside of the driveshaft housing
when the gear housing was removed, pull the water tube seal from the water tube.
1. Replace the water tube seal, if damaged.
2. Remove six screws, washers, and isolators (if equipped).
3. Remove the cover.
NOTE: Isolators from the forward two screws are shorter than the other isolators. Retain
these for proper reassembly.
NOTE: Early designs included isolators on the water pump housing screws. Newer design
versions did not use these isolators.

a
e

b
b

c
d

a - Water tube seal d - Isolators (6) if so equipped

b - Screw (6) M6 x 30 e - Cover
c - Washers (6)

IMPORTANT: The circular groove formed by the impeller sealing bead should be
disregarded when inspecting the cover and plate. The depth of the groove will not
affect the water pump output.
4. Replace the cover if thickness of the steel at the discharge slots is 1.524 mm (0.060 in.)
or less, or if the grooves other than impeller sealing bead grooves in the cover roof, are
more than 0.762 mm (0.030 in.) deep.
5. Lift the impeller, drive key, and gasket from the driveshaft.

c b

19220

a - Impeller
b - Drive key
c - Gasket

90-883064R02 JULY 2006 Page 6B-15

Non Bigfoot Gear Housing

6. Inspect the impeller. Replace the impeller if any of the following conditions exist:
• Impeller blades are cracked, torn, or worn.
• Impeller is glazed, or melted (caused by operation without sufficient water
supply).
• Rubber portion of the impeller is not bonded to the impeller hub.
7. Remove the face plate and gasket.
8. Replace the face plate if grooves, other than impeller sealing bead grooves in the plate,
are more than 0.762 mm (0.030 in.) deep.

a - Plate
b - Gasket

9. Remove the water pump base by lifting gently as shown. Inspect carefully for cracks.

a a

51206

55874

Old Style Base New Style Base

a - Water pump base

Page 6B-16 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

10. Remove, and discard seals, if damaged. Secure the base to a bench top or lightly clamp
base in a vise when removing seals.

51205

a - Seals

11. Remove the seal, and plate, if damaged or worn.

ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ
b

ÉÉÉÉÉÉÉ
a

51268

a - Seal
b - Plate

Bearing Carrier and Propeller Shaft

1. Remove the fasteners.

a 51117

a - Fasteners

90-883064R02 JULY 2006 Page 6B-17

Non Bigfoot Gear Housing

2. With the propeller shaft horizontal, use the bearing puller to remove the carrier from the
gear housing. Remove the propeller shaft components as an assembly, taking care not to
lose the cam follower.

b
e
c a 91-46086A1
91-58716

d 51116

a - Bearing carrier
b - Puller jaws
c - Puller bolt
d - Thrust hub
e - Propeller shaft
Puller Jaws 91-46086A1
Puller Bolt 91-85716

3. Replace the reverse gear if gear teeth or clutch teeth on the reverse gear are chipped or
worn. If the reverse gear must be replaced, pinion gear and sliding clutch should be
inspected for damage.
4. If the reverse gear bearing is rusted or does not roll freely, replace the bearing. Remove
bearing and reverse gear using the bearing puller tool.

a
91-27780

a - Bearing puller tool

Bearing Puller Tool 91-27780

Page 6B-18 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

5. Remove the ball bearing from the reverse gear using the universal puller plate and driver
head.

a d

91-37312T 91-37241
b c
51269

a - Ball bearing
b - Reverse gear
c - Universal puller plate
d - Driver head
Universal Puller Plate 91-37241
Driver Head 91-37312T

6. If the bearing is rusted or does not roll freely, replace the bearing. Remove the bearing
and oil seals. Discard the oil seals.

91-37323
a

b 91-37312T
c

a - Driver rod
b - Driver head
c - Propeller shaft needle bearing
d - Oil seals (2)
Driver Head 91-37312T
Driver Rod 91-37323

7. Remove the propeller shaft seals, and bearing carrier O-ring.

51263
a - O-ring

90-883064R02 JULY 2006 Page 6B-19

Non Bigfoot Gear Housing

Propeller Shaft Disassembly

1. Remove the spring. Push out the cross pin.

d
b

c
a

a - Spring
b - Cam follower
c - Apply pressure as shown
d - Punch
e - Cross pin

2. Replace the cam follower if worn or pitted on either end.

3. Replace the sliding clutch if jaws are rounded or chipped. Rounded jaws indicate the
following:
• Improper shift cable adjustment.
• Engine idle speed is too high while shifting.
• Shifting too slowly.
a e c

b
d 51265

a - Cam follower
b - Guide block
c - Spring
d - Sliding clutch
e - Jaws

Page 6B-20 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

4. Check bearing surfaces of the propeller shaft. If the shaft is worn or pitted, replace the
shaft and corresponding bearing.
5. Replace the propeller shaft if:
a. Splines are twisted or worn.
b. Bearing surfaces of the propeller shaft are pitted or worn.
c. Oil seal surface is grooved in excess of 0.12 mm (0.005 in.).
d. Shaft has a noticeable wobble, or is bent more than 0.152 mm (0.006 in.). Check with
a dial indicator and V-blocks.

c b

a 51139

a - V-blocks
b - Bearing surfaces
c - Check with dial indicator here

90-883064R02 JULY 2006 Page 6B-21

Non Bigfoot Gear Housing

Pinion Gear, Driveshaft and Forward Gear

1. Hold the driveshaft using the driveshaft holding tool. Remove and discard the pinion nut.
Driveshaft Holding Tool (4-Stroke) 91-877840A1

2. Remove the driveshaft, pinion gear, and forward gear.

3. Replace the pinion gear if chipped or worn.
4. Replace the lower driveshaft bearing if rusted, or damaged; or does not roll freely. To
remove, refer to Lower Driveshaft Bearing, following.
5. Replace the forward gear if gear teeth are chipped or worn.

e
a d

a - Pinion nut
b - Driveshaft
c - Pinion gear
d - Bearing
e - Forward gear

6. Replace the forward gear needle bearing if rusted or does not roll freely after cleaning
in solvent. Remove as shown.

a - Needle bearing

Page 6B-22 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

7. Replace the forward gear tapered roller bearing and race if either bearing or race are
rusted or damaged; or if bearing does not roll freely after cleaning in solvent. Remove
bearing from gear using a universal puller plate and mandrel. To remove the race, refer
to Forward Gear Bearing Race, following.

a c

91-37241
b
51119

a - Bearing/race
b - Universal puller plate
c - Mandrel
Universal Puller Plate 91-37241

Upper Driveshaft Bearing

1. Replace the bearing and race if either the bearing or race are rusted or damaged; or if
bearing does not roll freely after cleaning in solvent.

51271

a - Bearing

90-883064R02 JULY 2006 Page 6B-23

Non Bigfoot Gear Housing

Lower Driveshaft Bearing

1. Remove the lower driveshaft bearing using the lower driveshaft bearing driver assembly
with the bushing installed.

c
a

91-817058A1

51260

a - Bearing
b - Lower driveshaft bearing driver assembly
c - Bushing
Lower Driveshaft Bearing Driver Assembly 91-817058A1

Forward Gear Bearing Race

IMPORTANT: Retain shims for reassembly.
1. Remove the bearing race and shims using the bearing puller tool.

91-27780
c b
a

a - Race
b - Shims
c - Bearing puller tool
Bearing Puller Tool 91-27780

Page 6B-24 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Shift Shaft
1. Remove the shift shaft coupler, and spacer.

51271

a - Coupler
b - Spacer

2. Remove the shift shaft bushing, and shift shaft. Protect the shift shaft to prevent spline
damage.

51205
a - Shift shaft bushing
b - Shift shaft

3. Remove the shift shaft cam; replace if worn.

51117

a - Shift shaft cam (number down)

90-883064R02 JULY 2006 Page 6B-25

Non Bigfoot Gear Housing

NOTE: Remove any burrs or sharp edges on the shift shaft splines before removing the shift
shaft bushing.
4. Remove the shift shaft bushing, and E clip from the shift shaft. Replace the shift shaft
if splines are twisted or damaged on either end of the shaft. Remove and discard the
O-ring if damaged.
d
b c
a

51264

a - Shift shaft bushing

b - E clip
c - Shift shaft
d - O-ring

5. Remove and discard the seal if damaged.

51265
a - Seal

Page 6B-26 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Gear Housing Reassembly

Shift Shaft
1. Apply Loctite 271 Threadlocker on the O.D. of the new seal. Install with the seal lip up,
as shown.
2. Press the seal into the shift shaft bushing until the seal bottoms. Use a suitable tool.
3. Apply 2-4-C Marine Lubricant with Teflon on the O-ring and the I.D. of the seal.

95

a
7

51270

a - Seal lips facing up

b - Shift shaft bushing
c - Tool
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

7 Loctite 271 Threadlocker 92-809819 92-809819

4. Assemble the components.

95 d
b
c
a

51264
a - Shift shaft
b - E clip
c - Bushing
d - O-ring
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

90-883064R02 JULY 2006 Page 6B-27

Non Bigfoot Gear Housing

5. Install the shift cam; align the hole in the shift cam with the shift shaft pilot bore.

51117

a - Shift shaft pilot bore

b - Shift cam numbers down (4-Stroke)

6. Install the shift shaft assembly. Insert splines into the shift cam.

51268

a - Shift shaft assembly

Propeller Shaft
1. Install the components. Clutch should be installed with the long end (non-ratcheting)
toward the propeller shaft reverse shoulder.
d c a

95 e
b
a - Spring
b - Clutch (Align hole with slot in prop shaft)
c - Guide block
d - Cam follower (Hold in place with 2-4-C Marine Lubricant with Teflon)
e - Propeller shaft shoulder
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

Page 6B-28 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

2. Install the cross pin.

b
a
51268

a - Cross pin
b - Cam follower
c - Apply pressure in this direction

3. Install the spring.

NOTE: Spring windings must lay flat in the clutch groove. Do not allow the spring coils to
overlap each other.
a

51265
a - Spring

90-883064R02 JULY 2006 Page 6B-29

Non Bigfoot Gear Housing

Forward Gear Bearing Race

1. Place the shims, retained from the disassembly, into the housing. If the shims were lost
or damaged, or a new gearcase is being assembled, start with a 0.254 mm (0.010 in.)
shim.
2. Drive the bearing race into the housing. Use a lead hammer to avoid damage to the
propeller shaft.

d c a
b 4

91-817009 51265

a - Shim(s)
b - Forward gear bearing race driver cup
c - Propeller shaft
d - Assembled bearing carrier
Forward Gear Bearing Race Driver Cup 91-817009

Tube Ref. Description Mercury Part Number Quicksilver Part Number

No.
Needle Bearing Assembly 92-802868Q1 N/A
4 Lubricant

Bearing Carrier
1. Lubricate the O.D. of the needle bearing with 2-4-C Marine Lubricant with Teflon.
2. Install the needle bearing.
NOTE: Push against the numbered end of the bearing.

b
a

91-817011T

95

51269
a - Needle bearing
b - Installer
Needle Bearing Installer 91-817011T

Page 6B-30 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Tube Ref. Description Mercury Part Number Quicksilver Part Number

No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

3. Apply Loctite 271 Threadlocker on the O.D. of the small diameter oil seal. Seal lip should
face away from the shoulder on the installation tool. Press the seal in until the installer
tool bottoms out.

7 a
91-817007T

58209

a - Small diameter seal

b - Bearing carrier seal installer
Bearing Carrier Seal Installer 91-817007T

Tube Ref. Description Mercury Part Number Quicksilver Part Number

No.

7 Loctite 271 Threadlocker 92-809819 92-809819

4. Apply Loctite 271 Threadlocker on the O.D. of the larger diameter oil seal. Seal lip
should face towards the shoulder on the installation tool. Press in until the installer tool
bottoms out.

7
a 91-817007T

51263

a - Large diameter seal

b - Bearing carrier seal installer
Bearing Carrier Seal Installer 91-817007T

90-883064R02 JULY 2006 Page 6B-31

Non Bigfoot Gear Housing

Tube Ref. Description Mercury Part Number Quicksilver Part Number

No.

7 Loctite 271 Threadlocker 92-809819 92-809819

NOTE: If service tools are not available, the following reference dimensions apply for
installing the bearing, and seals to the proper depths.

20 mm (0.82 in.)

a
51275

a - Bearing

11 mm (0.44 in.)
1 mm (0.04 in.)

b
a

51275

a - Oil seal (Install with lip down)

b - Oil seal (Install with lip up)

Page 6B-32 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Reverse Gear
1. Lubricate the I.D. of the bearing with 2-4-C Marine Lubricant with Teflon. Use a suitable
mandrel and press onto the gear until the bearing bottoms out.

b
a

95

51205

a - Bearing
b - Suitable mandrel
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

2. Lubricate the O.D. of the bearing with 2-4-C Marine Lubricant with Teflon. Use a suitable
mandrel and press the reverse gear/bearing assembly into the bearing carrier until the
bearing bottoms out.

b
a

c
95

51264

a - Reverse gear and bearing assembly

b - Suitable mandrel
c - Bearing carrier
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

90-883064R02 JULY 2006 Page 6B-33

Non Bigfoot Gear Housing

Forward Gear
1. Lubricate the O.D. of the bearing with 2-4-C Marine Lubricant with Teflon. Press the new
propeller shaft bearing into the gear until the installer tool bottoms out.
NOTE: Push against the numbered end of the bearing.
91-817005

95

51291

a - Installer tool
Forward Gear Bearing Installer 91-817005
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

2. Lubricate the I.D. of the bearing with 2-4-C Marine Lubricant with Teflon. Use a suitable
mandrel and press the tapered roller bearing onto the gear until the bearing bottoms on
the gear.

b
95 a

51272

a - Bearing (Lubricate I.D. before assembly)

b - Suitable mandrel
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

Page 6B-34 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Lower Driveshaft Bearing Installation

1. Lubricate the O.D. of the bearing with 2-4-C Marine Lubricant with Teflon.
2. Install bearing into the housing. Press until the lower driveshaft bearing driver assembly
bottoms out.
NOTE: Push against the numbered end of the bearing.

179.0 mm
179.5 mm (
7.05 in.
7.07 in. ) b

95

c
91-817058A1

51260

a - Needle bearing (Lubricate O.D. before assembly)

b - Lower driveshaft bearing driver assembly
c - Reference (Bearing depth)
Lower Driveshaft Bearing Driver Assembly 91-817058A1

Tube Ref. Description Mercury Part Number Quicksilver Part Number

No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

90-883064R02 JULY 2006 Page 6B-35

Non Bigfoot Gear Housing

Upper Driveshaft Bearing Installation

1. Lubricate the I.D. of the bearing with 2-4-C Marine Lubricant with Teflon. Using a suitable
mandrel press the upper driveshaft bearing onto the driveshaft until the bearing contacts
the driveshaft shoulder.

95 a

51268

a - Upper driveshaft bearing (Lubricate I.D. before assembly)

Tube Ref. Description Mercury Part Number Quicksilver Part Number

No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

Page 6B-36 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Forward Gear, Pinion Gear, Upper Driveshaft Bearing Race, Retainer and
Driveshaft Installation
NOTE: If shims were lost, or are not reusable (damaged), start with approximately 0.361
mm (0.015 in.).
1. Install the components in the sequence shown.
a. Apply Premium Blend Gear Lubricant to the bearing rollers before installation.
b. Tighten the upper driveshaft bearing retainer to the specified torque using tool
91-43506T.
c. Install a new pinion nut with recessed toward pinion gear. See Note at Pinion Gear
Depth following.

g
91-43506T
e

87
f
b
g a

51263

Assembly Sequence
a - Forward gear/bearing
b - Pinion gear
c - Driveshaft
d - Upper driveshaft bearing race and shims
e - Upper driveshaft bearing retainer
f - Driveshaft holding tool
g - Pinion nut
Bearing Retaining Tool 91-43506T
Driveshaft Holding Tool (4-Stroke) 91-877840A1 (40/50/60)

Description Nm lb. in. lb. ft.

Upper driveshaft bearing retainer 101.7 75

90-883064R02 JULY 2006 Page 6B-37

Non Bigfoot Gear Housing

Pinion Gear Location and Forward Gear Backlash

DETERMINING PINION GEAR LOCATION
NOTE: Read the entire procedure before attempting any change in shim thickness.
IMPORTANT: Forward gear assembly pilots the end of the pinion gauge and must be
installed in the gear housing when checking the pinion gear depth. Without it an
inaccurate measurement will be obtained.
1. Clean the gear housing bearing carrier shoulder, and diameter.
2. Position the gear housing upright (driveshaft vertical). Install the bearing preload tool in
the sequence shown.
a. Ensure all bearing and thrust washer surfaces are clean and free of nicks.
b. Lubricate thrust bearing. Ensure that it can move freely.
c. Thread nut all the way onto bolt. Bolt must be snug against the spring.
d. Holes in sleeve must align with the set screws.
e. Tighten the set screws against the driveshaft. Bolt should not slide on the driveshaft.

h 19 mm (3/4 in.) I.D.

i i

g
f
e

51270

INSTALLATION SEQUENCE: Bearing Preload Tool

a - Plate f - Nut
b - Adapter g - Bolt
c - Thrust h - Sleeve
d - Thrust washer i - Set screw (2)
e - Spring
Bearing Preload Tool 91-14311A2

Page 6B-38 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

3. Measure the distance between the top of the nut and the bottom of the bolt head.
4. Increase the distance by 25.4 mm (1 in.).
5. Rotate the driveshaft 10 revolutions. This properly seats the upper driveshaft tapered
roller bearing.

c
a

19884

a - Distance, 25.4 mm (1 in.)

b - Nut
c - Bolt

6. Insert the pinion gear location tool. Position the access hole as shown. Insert the feeler
gauge between the gauging surface and pinion gear.
a b c d

91-817008A2

51265

a - Pinion gear location tool

b - Access hole
c - Gauging surface
d - Pinion gear
Pinion Gear Location Tool 91-817008A2

90-883064R02 JULY 2006 Page 6B-39

Non Bigfoot Gear Housing

7. The correct clearance between the gauging surface and the pinion gear is 0.64 mm
(0.025 in.).
8. If clearance is more than 0.64 mm (0.025 in.), remove shims from under the upper
bearing cup. If clearance is less than 0.64 mm (0.025 in.), add shims under the upper
bearing race.
9. After the final adjustment to the pinion height, and the forward gear backlash has been
established, apply Loctite 271 Threadlocker to the threads, and torque the new pinion
nut to the specified torque.
NOTE: Clean driveshaft and pinion nut threads with Loctite Primer or suitable degreaser
before applying Loctite 271 Threadlocker.

51285

51263

a - Bearing race
b - Shims
c - Pinion nut (Recessed side toward pinion)
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

117 Loctite Primer N 92-809824 92-809824

Description Nm lb. in. lb. ft.

Pinion nut 67 50

Page 6B-40 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Determining Forward Gear Backlash

NOTE: Read the entire procedure before attempting any change in shim thickness.
1. Obtain correct pinion gear location; refer to Determining Pinion Gear Location,
preceding.
2. Install the bearing preload tool on the driveshaft; refer to Determining Pinion Gear
Location, preceding.
3. Install the components as shown.
4. While holding the driveshaft, torque the puller bolt to specification.
5. Rotate the driveshaft 5 - 10 revolutions. This should properly seat the forward gear
tapered roller bearing. Repeat step 4.

91-46086A1
91-58716
d a b

51119

c
a - Propeller shaft*
b - Bearing carrier* (Assembled)
c - Puller jaws
d - Puller bolt
Puller Jaws 91-46086A1
Puller Bolt 91-85716

Description Nm lb. in. lb. ft.

Puller bolt 5.1 45

*Refer to Bearing Carrier and Propeller Shaft Installation, following.

90-883064R02 JULY 2006 Page 6B-41

Non Bigfoot Gear Housing

6. Install the components as shown.

e f

d c

91-83155
a

91-58222A1

91-19660--1
b c 51117

a - Threaded rod (Obtain d - Dial indicator adapter kit

locally) e - Dial indicator
b - Washers f - Backlash indicator tool
c - Nuts
Dial Indicator Adapter Kit 91-83155
Dial Indicator 91-58222A1
Backlash Indicator Tool 91-19660--1
7. Position dial indicator on the appropriate line (from chart) marked on the backlash
indicator tool.
Backlash indicator tool
Align pointer of dial indicator with mark 4 or 9.3 mm (0.366 in.)
8. Turn the driveshaft back-and-forth (check for no rotation at the propeller shaft).
9. Dial indicator registers the amount of backlash, which must be between specifications
shown in the chart.
Dial indicator
Minimum 0.28 mm (0.011 in.)
Maximum 0.43 mm (0.017 in.)
10. If the backlash is less than the minimum reading, remove shims from in front of the
forward gear bearing race. If the backlash is more than the maximum reading, add shims
in front of the forward gear bearing race. When the final measurement has been made,
apply Loctite 271 Threadlocker to the threads of the pinion nut.
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

NOTE: By adding or subtracting 0.025 mm (0.001 in.) shim, the backlash will change 0.032 mm
(0.001 in.).

Page 6B-42 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Bearing Carrier and Propeller Shaft Installation

1. Lubricate O-ring, bearing carrier and related gearcase housing bores, in areas shown,
with 2-4-C Marine Lubricant with Teflon.
2. Insert the propeller shaft assembly into the bearing carrier.
3. Install the bearing carrier, and propeller shaft assembly into the gear housing. Use care
not to displace the cam follower.

a b
95 51271

a - O-ring
b - Cam follower
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

4. Install the flat washers and bolts.

a
b

a - Bolt (10-855940-30) 30 mm (1.18 in.) long

b - Flat washer (12-855941) 2.29 mm (0.090 in.)

90-883064R02 JULY 2006 Page 6B-43

Non Bigfoot Gear Housing

5. Tighten the bolts to the specified torque.

7 51117

a - Bolt and washer (2) M8 x 30

Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

Description Nm lb. in. lb. ft.

Bearing carrier bolt 25.5 18.8

Water Pump Reassembly and Installation

1. Place seal on the longer shoulder side of the tool. Seal spring should face the shoulder
of the tool during installation. Apply Loctite 271 Threadlocker to the O.D. of the seal.
2. Press into the water pump base until the tool bottoms out.

7
91-817006
a

55876

a - Seal
b - Water pump base seal installer
Water Pump Base Seal Installer 91-817006

Tube Ref. Description Mercury Part Number Quicksilver Part Number

No.

7 Loctite 271 Threadlocker 92-809819 92-809819

Page 6B-44 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

3. Place seal on the shorter shoulder side of the tool. Seal spring should face the shoulder
of the tool during the installation. Apply Loctite 271 Threadlocker to the O.D. of the seal.
4. Press into the water pump base until the tool bottoms out.

b 91-817006
a

55877

a - Seal
b - Shorter side of tool
c - Seal installation tool
Water Pump Base Seal Installer 91-817006

Tube Ref. Description Mercury Part Number Quicksilver Part Number

No.

7 Loctite 271 Threadlocker 92-809819 92-809819

NOTE: If the installation tool is not available, press seals in as shown to the depths indicated.
1.02 mm (0.04 in.)
a

55878

a - Seal (Install with spring visible when installed)

b - Seal (Install with spring visible when installed)
c - Seal bottom

90-883064R02 JULY 2006 Page 6B-45

Non Bigfoot Gear Housing

5. Install the O-ring. Apply 2-4-C Marine Lubricant with Teflon to the O-ring, seal lips, and
gear housing bore.
6. Install the water pump base into the gearcase.

95

55879

a - O-ring
b - Water pump base
c - Gearcase
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

7. If removed previously, reinstall the seal, and the filler plate.

ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ
b

a
ÉÉÉÉÉÉÉ

51268

a - Seal
b - Filler plate

Page 6B-46 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

8. Install the gasket, and the face plate.

51293

a - Gasket
b - Face plate

IMPORTANT: If the old impeller is reused, install in the original (clockwise) direction
of rotation.
9. Install the drive key, and the impeller.

51292

a - Drive key
b - Impeller

10. Lubricate the I.D. of the cover with 2-4-C Marine Lubricant with Teflon. Install the gasket
with the bead facing toward the cover.
95
b
a

51290

a - Gasket
b - Bead toward cover
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

90-883064R02 JULY 2006 Page 6B-47

Non Bigfoot Gear Housing

11. Rotate the driveshaft clockwise, and push the water pump housing down.
12. Apply Loctite 271 Threadlocker on the threads, and tighten the screws to the specified
torque (in sequence shown).

c d
d d
c

b b c
51275

a - Water pump housing assembly

b - Isolators (If equipped) Note: Two isolators for the forward screws are different
from the remaining four isolators
c - Washers (6)
d - Screw (6) M6 x 16
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

NOTE: Torque the cover screws as shown.

1 3

4 2

51271

Description Nm lb. in. lb. ft.

Cover screw 6.8 60

13. If the water tube seal remained on the water tube in the driveshaft housing, pull the seal
from the water tube.

Page 6B-48 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

14. Lubricate the I.D. of the water tube seal with 2-4-C Marine Lubricant with Teflon, and
install.

51206

a - Water tube seal

Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

Gear Housing Pressure Test

1. Remove the vent plug, and install the pressure test gauge. Tighten securely.

2. Pressurize the housing to 69 - 83 kPa (10 - 12 psi), and observe the gauge for five
minutes.

Gearcase test pressure

Applied air pressure 69 - 83 kPa (10 - 12 psi)
Length of time Five minutes

90-883064R02 JULY 2006 Page 6B-49

Non Bigfoot Gear Housing

3. Rotate the driveshaft, propeller shaft, and move the shift rod while the housing is
pressurized to check for leaks.

4. If pressure drop is noted, immerse the housing in water.

5. Repressurize to 69 - 83 kPa (10 - 12 psi), and check for air bubbles.
6. Replace leaking seals as necessary. Retest the housing.
NOTE: Gearcase assembly should hold 69 - 83 kPa (10 - 12 psi) for five minutes.

Gearcase test pressure

Applied air pressure 69 - 83 kPa (10 - 12 psi)
Length of time Five minutes

7. Remove the tester from the housing. Install the vent plug, and the new sealing washers.

Page 6B-50 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Gear Housing Installation

WARNING
Disconnect and isolate the spark plug leads before installing the gear housing
onto the driveshaft housing.
1. Position the shift linkage into the forward gear position.

b
a
Remote Control Model Shown
a - Shift lever - 40 EFI (4-Stroke)
b - Shift lever - 40 Carb (4-Stroke)
2. Tilt engine to the full up position. Engage tilt lock lever.
3. Shift the gear housing into neutral. Propeller shaft will rotate freely in either direction.
4. Install the water tube seal, spacer, and shift shaft coupler.
95

a c

51206

a - Water tube seal

b - Spacer
c - Shift shaft coupler
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

CAUTION
Do not lubricate top of driveshaft. Excess lubricant will not allow driveshaft to fully
engage crankshaft. Tightening the gear housing fasteners (if excess lubricant is on
top of the driveshaft) will load the driveshaft/crankshaft and may damage either or
both powerhead and gear housing. Wipe the top of the driveshaft free of lubricant.
5. Lightly apply 2-4-C Marine Lubricant with Teflon onto the driveshaft splines.

90-883064R02 JULY 2006 Page 6B-51

Non Bigfoot Gear Housing

6. Shift gear housing into forward gear. The gear housing will not engage when the
propeller shaft is turned clockwise.
7. Position the driveshaft into the driveshaft housing. Move the gear housing towards the
driveshaft housing while aligning the shift shaft coupler, water tube seal, and driveshaft
splines.
NOTE: If the driveshaft splines will not align with the crankshaft splines, install a propeller
and turn the propeller shaft counterclockwise while pushing the gear housing onto the
driveshaft housing. It may also be necessary to move the shift block (on the powerhead) to
align the shift shaft splines for proper reassembly.
8. Install four bolts and washers (two on each side). Apply Loctite 271 Threadlocker on the
bottom half of the bolt threads prior to installation.
9. Install the locknut and washer.
10. Torque the bolts, and locknut to the specified torque.

7 a
b

50551

a - Bolts and washers (4) M10 x 45

b - Locknut and washer
Tube Ref. Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

Description Nm lb. in. lb. ft.

Bolts and locknut 54 40

11. Check shift operation.

a. Propeller shaft will not rotate in counterclockwise direction when in forward gear.
Clutch will ratchet (clicking noise) when rotated clockwise.
b. Propeller shaft will rotate freely in either direction when gearcase is in neutral.
c. Propeller shaft will not rotate in either direction when gearcase is in reverse.
IMPORTANT: If shift operation is not as described, remove the gear housing and
correct the shift operation.

Page 6B-52 90-883064R02 JULY 2006

 Non Bigfoot Gear Housing

Filling Gear Housing with Lubricant

NOTE: Gear housing lubricant capacity is approximately 340 ml (11.5 fl. oz.).

WARNING
If a gear housing is installed on an outboard, disconnect and isolate the spark plug
leads from the spark plugs before working near the propeller.

CAUTION
Do not use automotive grease in the gear housing. Use only Premium Gear
Lubricant.
1. Remove any gasket material from the fill/drain and vent plugs, and gear housing. Install
new sealing washers on the fill/drain and vent plugs.
IMPORTANT: Never add lubricant without removing the vent plugs. The gear housing
cannot be filled because of trapped air. Fill the gear housing when the driveshaft is
in a vertical position.
2. Remove the fill/drain plug and sealing washer.
3. Insert lubricant tube in the fill/drain hole, then remove vent plugs and sealing washer.
4. Fill until excess lubricant flows out of the left vent hole.
5. Replace the left vent plug and sealing washer, and continue to fill until the lubricant flows
from the right vent hole.
6. Replace the right vent plug and sealing washer.
7. Install fill/drain plug and sealing washer.
8. Torque the screws to the specified torque.

b
c

a 50558

a - Fill/drain plug
b - Vent plug
c - Vent plug
Tube Ref. Description Mercury Part Number Quicksilver Part
No. Number

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

Description Nm lb. in. lb. ft.

Screw 6.5 58

90-883064R02 JULY 2006 Page 6B-53

Non Bigfoot Gear Housing

Trim Tab Adjustment and Replacement

IMPORTANT: The trim tab is made of a special alloy to aid in protecting the driveshaft
housing and gear housing from galvanic corrosion (corrosion and pitting of metal
surfaces). Do not paint or place protective coating on the trim tab, or trim tab corro-
sion protection function will be lost.
1. Replace trim tab if 50% (or more) corroded. Mark the location of the old trim tab on the
anti-ventilation plate before removal; install the new trim tab in the same location.
2. The trim tab will offset (balance) some of the steering load that is caused by propeller
torque at higher speeds. If at higher speeds the boat turns more easily to the left, loosen
the screw, move the trim tab (trailing edge) to the left (when viewed from behind);
retighten screw. Turn trim tab (trailing edge) to the right if the boat turns more easily to
the right.

a
c

50553

a - Trim tab
b - Anti-ventilation plate
c - Retaining screw (M10 x 30) and washer
Description Nm lb. in. lb. ft.
Retaining screw 29.8 22

Page 6B-54 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Lower Unit
Section 6C - Bigfoot Gear Housing
Table of Contents
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-2 Forward Gear Bearing Race . . . . . . . . . . . 6C-31
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-7 Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-32
Gear Housing (Driveshaft) Bearing Carrier Reassembly . . . . . . . . . . . 6C-35
(2.31:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . 6C-8 Forward Gear Reassembly . . . . . . . . . . . . 6C-39
Gear Housing (Propeller Shaft) Propeller Shaft Reassembly . . . . . . . . . . . 6C-41
(2.31:1 Gear Ratio) . . . . . . . . . . . . . . . . . . . . . 6C-10 Driveshaft Wear Sleeve Installation . . . . . 6C-42
General Service Recommendations . . . . . . . 6C-12 Driveshaft Lower Bearing Race
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-44
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-12 Oil Sleeve Installation . . . . . . . . . . . . . . . . . 6C-45
Draining and Inspecting Gear Lubricant . . . . 6C-13 Driveshaft Upper Bearing Installation . . . 6C-45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-14 Forward Gear, Driveshaft Lower Bearing, Pinion
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-15 Gear, and Driveshaft Installation . . . . . . . . 6C-47
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6C-15 Pinion Gear Depth and Forward Gear
Bearing Carrier and Propeller Shaft . . . . . 6C-18 Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-48
Pinion Gear, Driveshaft, and Forward Bearing Carrier and Propeller Shaft
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-23 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-53
Upper Driveshaft Bearing . . . . . . . . . . . . . .
Oil Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . .
6C-26
6C-27
Water Pump Reassembly and Installation 6C-55
Gear Housing Pressure Test . . . . . . . . . . . 6C-58 6
Lower Driveshaft Bearing Race . . . . . . . . 6C-28 Filling Gear Housing With Lubricant . . . . . . . 6C-60 C
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-29 Gearcase Installation . . . . . . . . . . . . . . . . . . . . 6C-61
Forward Gear Bearing Race . . . . . . . . . . . 6C-31 Trim Tab Adjustment and Replacement . . 6C-64
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-31

90-883064R02 JULY 2006 Page 6C-1

Bigfoot Gear Housing

Special Tools
1. Pinion Gear Locating Tool (P/N 91-12349A05)

Disc 3 Disc 1

Disc 2

55079

2. Bearing Installation Tool (P/N 91-13945)

3. Oil Seal Driver (P/N 91-13949)

4. Bearing Race Tool (P/N 91-14308T02)

Page 6C-2 90-883064R02 JULY 2006

 Bigfoot Gear Housing

5. Bearing Installation (P/N 91-14309T02)

6. Wear Sleeve Installation Tool (P/N 91-14310T1)

7. Bearing Preload Tool (P/N 91-14311A04)

8. Mandrel (P/N 91-15755T)

73815

9. Backlash Indicator Tool (P/N 91-19660--1) 2.07:1 Gear Ratio (14/29)

19660--1

10. Mandrel (P/N 91-31106T)

90-883064R02 JULY 2006 Page 6C-3

Bigfoot Gear Housing

11. Oil Seal Driver (P/N 91-31108T)

12. Threaded Rod (P/N 91-31229) and Nut (P/N 91-24156)

13. Slide Hammer (P/N 91-34569A1)

14. Mandrel (P/N 91-36569T)

15. Universal Puller Plate (P/N 91-37241)

73652

16. Driver Rod (P/N 91-37323)

74184

17. Mandrel (P/N 91-37350T)

Page 6C-4 90-883064R02 JULY 2006

 Bigfoot Gear Housing

18. Puller Jaws (P/N 91-46086A1)

19. Driveshaft Holding Tool (P/N 91-56775T; 40/50 4-Stroke, 747cc/935cc),

(P/N 91-877840A1; 40/50/60 4-Stroke, 995cc)

20. Dial Indicator (P/N 91-58222A1)

21. Backlash Indicator Tool (P/N 91-78473) 2.31:1 Gear Ratio (13/30)

22. Puller Bolt (P/N 91-85716)

23. Dial Indicator Adapter Kit (P/N 91-83155)

90-883064R02 JULY 2006 Page 6C-5

Bigfoot Gear Housing

24. Bearing Puller Assembly (P/N 91-83165T)

25. Bearing Installation Tool (P/N 91-856875A1)

56783

26. Bearing Installation Tool (P/N 91-877321A1)

Page 6C-6 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Specifications
Gear Ratio 2.31:1
Gearcase Capacity 710 ml (24.0 fl. oz.)
Lubricant Type Premium Gear Lubricant
Forward Gear
Number of Teeth 30 Spiral/Bevel
Pinion Gear
Number of Teeth 13 Spiral/Bevel
Pinion Height 0.64 mm (0.025 in.)
Gear Housing Pinion Gear Locating Tool 91-12349A05
Bigfoot Flat Number #8
(2.31:1) Disc Number #3
Forward Gear Backlash 0.30 - 0.48 mm (0.012 - 0.019 in.)
Backlash Indicating Tool 91-78473
Mark Number #4
Water Pressure
@ 800 RPM 14 - 41 kPa (2 - 6 psi)
@ 6000 RPM (WOT) 83 - 172 kPa (12 - 25 psi)
Leak Test Pressure 69 - 83 kPa (10 - 12 psi)
for five minutes

90-883064R02 JULY 2006 Page 6C-7

Bigfoot Gear Housing

Gear Housing (Driveshaft) (2.31:1 Gear Ratio)

31
32 7
107.95 mm/4.25 in.
Torpedo dia.
29 21 Bigfoot
95
22 7
34 95
33
28

30
35 20
24
7
7 40 41
23

26 7
27 38
25 95 39
95
7 95
11
37
10

14 95 36
12
19
95

18
82

8 3
9
6

12
1
13
7 2

17
15
16 5
4
5
7 4
5
4

Page 6C-8 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Gear Housing (Driveshaft) (2.31:1 Gear Ratio)

Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
- 1 Gear housing
1 1 Gear housing assembly
2 1 Dowel pin
3 1 Oiler tube
4 3 Drain screw 7 60
5 3 Washer - Sealing
6 1 Dowel pin
7 1 Trim tab
8 1 Screw (.437-14 x 1.25) 30 22
9 1 Washer
10 1 Carrier
11 1 Needle bearing
12 2 Anode
13 1 Nut
14 1 Screw (M6 x 40) 7 60
15 1 Pinion gear (13 teeth)
16 1 Nut 95 70
17 1 Shift cam
18 1 Tapered roller bearing
19 AR Shim
20 1 Driveshaft assembly
21 1 Wear sleeve assembly
22 1 Ring seal
23 1 Cover assembly
24 1 Gasket
25 1 Gasket
26 1 Oil seal
27 1 Oil seal
28 1 Gasket
29 1 Water pump assembly
30 1 Face plate
31 4 Screw (M6 x 30) 7 60
32 1 Seal
33 1 Key
34 1 Impeller
35 6 Screw 7 60
36 1 Shift shaft assembly
37 1 E-ring
38 1 Bushing assembly
39 1 O-ring
40 1 Oil seal
41 2 Screw (M6 x 1) 7 60
Tube Ref. Quicksilver Part
Description Mercury Part Number
No. Number
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon
82 Premium Gear Lubricant 92-802846A1 92-802846Q1

7 Loctite 271 Threadlocker 92-809819 92-809819

90-883064R02 JULY 2006 Page 6C-9

Bigfoot Gear Housing

Gear Housing (Propeller Shaft) (2.31:1 Gear Ratio)

95
107.95 mm/4.25 in.
70 1
69 Torpedo dia.
50
Bigfoot
44
48
49 47
45
46 42 82

43
67 68

95 75

57 68

95 95 74
55

72
54
73

53
52
51
7 7

65
66
64

95

82
71
60
59
58

56
95
61
95
62

63

Page 6C-10 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Gear Housing (Propeller Shaft) (2.31:1 Gear Ratio)

Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
1 1 Gear housing assembly
42 1 Tapered roller bearing assembly
43 1 Cup
44 1 Forward gear (30 teeth)
45 1 Roller bearing
46 1 Retaining ring
47 1 Cam follower assembly
48 3 Ball
49 1 Slide
50 1 Spring
51 1 Clutch
52 1 Cross pin
53 1 Spring
54 1 Propeller shaft
55 1 Reverse gear (30 teeth)
56 1 Bearing carrier assembly
57 1 O-ring
58 1 Roller bearing
59 1 Oil seal
60 1 Oil seal
61 1 Roller bearing
62 1 Thrust washer
63 1 Thrust bearing
64 2 Stud 135 100
65 2 Washer
66 2 Nut 30 22
67 AR Shim
68 2 Thread insert
69 1 Decal
70 1 Decal - prop operation
71 1 Thrust hub assembly
72 1 Propeller nut assembly Service items
73 1 Tab washer
74 4 Screw 54 40
75 4 Washer

Tube Ref. Quicksilver Part

Description Mercury Part Number
No. Number
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon
82 Premium Gear Lubricant 92-802846A1 92-802846Q1

7 Loctite 271 Threadlocker 92-809819 92-809819

90-883064R02 JULY 2006 Page 6C-11

Bigfoot Gear Housing

General Service Recommendations

There may be more than one way to disassemble or reassemble a particular part. Therefore,
it is recommended that the entire procedure be read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
In many cases, disassembly of a sub-assembly may not be necessary until cleaning and
inspection reveals that disassembly is required for replacement of one or more components.
The service procedure order in this section is a normal disassembly, reassembly sequence.
The threaded parts are right hand, unless otherwise indicated.
When holding, pressing, or driving is required, use soft metal vise jaw protectors or wood
for protection of parts. Use a suitable mandrel, one that will contact only the bearing race
when pressing or driving bearings.
Whenever compressed air is used to dry a part, verify that no water is present in the air line.

Bearings
All bearings must be cleaned and inspected. Clean bearings with solvent, and dry with
compressed air. Air should be directed at the bearing so that it passes through the bearing.
Do not spin bearing with compressed air, as this may cause bearing to score from lack of
lubrication. After cleaning, lubricate bearings with Premium Gear Lubricant. Do not lubricate
the tapered bearing cups until after inspection.
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lube 92-802846A1 92-802846Q1

Inspect all bearings for roughness, catches, and bearing race side wear. Work inner bearing
race in-and-out, while holding outer race, to check for side wear. When inspecting tapered
bearings, determine the condition of the rollers, and the inner bearing race by inspecting the
bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles, and/or
discoloration from overheating. Always replace the tapered bearing and race as a set.
Inspect the gear housing for bearing races that have spun in their respective bores. If a race
has spun, the gear housing must be replaced.
Roller bearing condition is determined by inspecting the surface of the shaft that the roller
bearing supports. Check shaft surface for pitting, scoring, grooving, imbedded particles,
uneven wear, and/or discoloration from overheating. The shaft, and bearing must be
replaced if such a condition exists.

Seals
As a normal procedure, all O-rings and oil seals should be replaced without regard to
appearance. To prevent leakage around the seals, apply Loctite 271 Threadlocker to the
outer diameter of all metal case seals. When using Loctite on seals or threads, the surfaces
must be clean and dry. Apply 2-4-C Marine Lubricant with Teflon on all O-rings, and on the
I.D. of the oil seals. Apply 2-4-C Marine Lubricant with Teflon to the external surfaces of the
bearing carrier.
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

7 Loctite 271 Threadlocker 92-809819 92-809819

Page 6C-12 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Draining and Inspecting Gear Lubricant

WARNING
If a gear housing is installed on an outboard, avoid accidental starting before
working near the propeller. Disconnect and isolate the spark plug leads from the
spark plugs.
1. With the gear housing in a normal running position, place a clean pan under the housing;
remove the two vent screws, and one fill/drain screw with the gaskets.

c b

53922

a - Fill/drain screw
b - Oil level screw
c - Vent screw

2. Inspect the gear lubricant for metal particles. Drain the lubricant into a clean
pan/container. The presence of fine metal particles resembling powder in the gear
lubricant indicates normal wear. The presence of metal chips in the gear lubricant
indicates the need for gear housing disassembly, and component inspection.
3. Note the color of the gear lubricant. White or cream color may indicate presence of water
in the lubricant. Gear lubricant which has been drained from a gearcase recently in
operation will have a yellowish color due to lubricant agitation/aeration. Gear lubricant
which is mixed with assembly lubricant Special Lubricant 101 or 2-4-C Marine Lubricant
with Teflon, will also be creamy white in color. This is normal and should not be confused
with the presence of water. If water is suspected to be present in the gearcase, a
pressure check of the gearcase should be made with no lubricant in the gearcase. The
gearcase should hold 69 - 83 kPa (10 - 12 psi) of pressure for five minutes without
leaking down. Pouring a portion of the gear lubricant into a glass jar, and allowing the
lubricant to settle will allow any water in the lubricant to separate, and settle to the bottom
of the jar.
4. Presence of water in the gear lubricant indicates the need for disassembly, and
inspection of oil seals, seal surfaces, O-rings, water pump gaskets, and gear housing
components for damage. If the gearcase is rebuilt, the gearcase should be pressure
checked before filling with lubricant.

90-883064R02 JULY 2006 Page 6C-13

Bigfoot Gear Housing

Removal
WARNING
To prevent accidental engine starting, remove and isolate the spark plug leads from
the spark plugs before removing the gear housing.

1. Remove and isolate the spark plug leads from the spark plugs.
2. Shift the engine into forward gear.
3. Tilt the engine to full up position.
4. Remove four fasteners.
5. Remove the locknut and washer.
6. Remove the gear housing.

a
b

53992

a - Fasteners - Two each side

b - Locknut and washer

Page 6C-14 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Disassembly
Water Pump
NOTE: If the water tube seal remained on the water tube inside of the driveshaft housing
when the gear housing was removed, pull the water tube seal from the water tube.
NOTE: Newer models will not have isolators installed on the water pump.
1. Replace the water tube seal, if damaged.
2. Remove four screws (two on each side of the water pump housing), washers, and
isolators.
3. Remove the cover.

a
c

19212

a - Water tube seal

b - Screw, washer, isolator
c - Cover

IMPORTANT: The circular groove formed by the impeller sealing bead should be dis-
regarded when inspecting the cover and face plate. The depth of the groove will not
affect the water pump output.
4. Replace the cover if thickness of the steel at the discharge slots is 1.524 mm (0.060 in.)
or less, or if the grooves (other than impeller sealing bead grooves) in the water pump
cover, are more than 0.762 mm (0.030 in.) deep.
5. Lift the impeller, drive key, and gasket from the driveshaft.

c b

19220

a - Impeller
b - Drive key
c - Gasket

90-883064R02 JULY 2006 Page 6C-15

Bigfoot Gear Housing

6. Inspect the impeller. Replace the impeller if any of the following conditions exist:
• Impeller blades are cracked, torn, or worn.
• Impeller is glazed or melted.
• Rubber portion of the impeller is not bonded to the impeller hub.
7. Remove the face plate and gasket.
8. Replace the face plate if grooves, other than impeller sealing bead groove in the plate,
are more than 0.762 mm (0.030 in.) deep.
c
a

19219

a - Face plate
b - Gasket
c - Impeller sealing groove

9. Remove the screws and washers.

19217

a - Screws and washers

Page 6C-16 90-883064R02 JULY 2006

 Bigfoot Gear Housing

10. Remove the water pump base using flat screwdrivers to lightly pry up on the base.

19226

a - Water pump base

11. Remove, and discard seals.

19195

a - Seals

12. Remove the gasket.

19218

a - Gasket

90-883064R02 JULY 2006 Page 6C-17

Bigfoot Gear Housing

Bearing Carrier and Propeller Shaft

1. Remove the fasteners.

a
51117

a - Fasteners

2. With the propeller shaft horizontal, pull the carrier to break the seal with the gear
housing.
3. Remove the bearing carrier and propeller shaft components as an assembly, by pulling
back on the propeller shaft. Take care not to lose the cam follower or three metal balls
in the end of the propeller shaft.
4. Remove the propeller shaft from the bearing carrier.

b
e
c a

d 51116

a - Bearing carrier
b - Puller jaws
c - Puller bolt
d - Thrust hub
e - Propeller shaft
Puller Jaws 91-46086A1
Puller Bolt 91-85716

Page 6C-18 90-883064R02 JULY 2006

 Bigfoot Gear Housing

5. Lift the reverse gear, thrust bearing, and thrust washer from the bearing carrier. Replace
the thrust bearing, and thrust washer if rusted or damaged.
6. Replace the reverse gear if gear teeth or clutch teeth are rounded or chipped. If the
reverse gear must be replaced, pinion gear and sliding clutch should be inspected for
damage.

19202

a - Reverse gear
b - Thrust bearing
c - Thrust washer

7. If the reverse gear radial bearing is rusted or does not roll freely, replace the bearing.
If the bearing needs to be replaced, remove it using a slide hammer.
a

19205

a - Radial bearing
b - Slide hammer
Slide Hammer 91-34569A1

90-883064R02 JULY 2006 Page 6C-19

Bigfoot Gear Housing

8. If the propeller shaft roller bearing is rusted, or does not roll freely, replace the bearing. If
replacement is necessary, remove the bearing and oil seals using a mandrel and driver
rod. Discard oil seals.

58205

a - Propeller shaft roller bearing

b - Mandrel
c - Driver rod
Mandrel 91-36569T
Driver Rod 91-37323

9. Remove the propeller shaft seals, and bearing carrier O-ring.

51263

a - O-ring

Page 6C-20 90-883064R02 JULY 2006

 Bigfoot Gear Housing

10. Remove the spring.

51876

a - Spring

11. Apply constant pressure to the cam follower in order to prevent it, and internal
components from ejecting out of the propeller shaft during removal of the cross pin from
the clutch.

51800
a
a - Cross pin
b - Cam follower

90-883064R02 JULY 2006 Page 6C-21

Bigfoot Gear Housing

12. Remove components from the propeller shaft.

13. Replace the cam follower if worn or pitted.
14. Replace the sliding clutch if jaws are rounded or chipped. Rounded jaws indicate one
or more of the following:
• Improper shift cable adjustment.
• Engine idle speed is too high while shifting.
• Shifting from neutral into forward or reverse too slowly.

f c
a

b e d 51265

a - Cam follower
b - Metal balls (3)
c - Guide block
d - Spring
e - Sliding clutch
f - Jaws

15. Replace the propeller shaft if any of the following exist:

• Splines are twisted or worn.
• Bearing surfaces of the propeller shaft are pitted or worn.
• Oil seal surface is grooved.
• Shaft has a noticeable wobble, or is bent more than 0.228 mm (0.009 in.). Propeller
shaft trueness should be measured with a dial indicator with the propeller shaft on
V-blocks.

c b b

a 51877

a - V-blocks
b - Bearing surfaces
c - Measure with dial indicator at this point
Dial Indicator 91-58222A1

Page 6C-22 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Pinion Gear, Driveshaft, and Forward Gear

1. Hold the driveshaft using the driveshaft holding tool. Remove and discard pinion nut.
2. Remove the driveshaft, pinion gear, pinion bearing, and forward gear.
3. Replace the pinion gear if chipped or worn.
4. Replace the pinion bearing and race if either are rusted, pitted or damaged; or if bearing
does not roll freely.
5. Replace the forward gear if gear teeth or clutch teeth are chipped or worn.
a
c

d
b

f
19175

a - Driveshaft holding tool

b - Pinion nut
c - Driveshaft
d - Pinion gear
e - Pinion bearing
f - Forward gear
Driveshaft Holding Tool 91-56775T

90-883064R02 JULY 2006 Page 6C-23

Bigfoot Gear Housing

6. Replace the forward gear needle bearing if it is rusted or does not roll freely.
7. Use suitable tools to remove the retaining ring. Use a punch and hammer to remove the
bearing.

57905
b 19203

a - Retaining ring
b - Forward gear needle bearing

8. Replace the forward gear bearing and race if either are rusted, pitted or damaged; or
if bearing does not roll freely. Remove bearing from gear using the universal puller plate
and mandrel.

a c

b
51119

a - Forward gear bearing

b - Universal puller plate
c - Mandrel
Universal Puller Plate 91-37241

Page 6C-24 90-883064R02 JULY 2006

 Bigfoot Gear Housing

9. Replace the driveshaft if splines are worn or twisted.

10. If the bearing surface is damaged, replace the driveshaft, and corresponding bearing.
11. If the wear sleeve is deeply grooved allowing water to enter the gearcase, remove and
discard the sleeve using a universal puller plate and mallet.

d e

19710

a - Crankshaft/driveshaft splines
b - Mallet
c - Bearing surface
d - Wear sleeve
e - Universal puller plate
Universal Puller Plate 91-37241

12. Remove and discard the rubber ring.

a

19152

a - Rubber ring

90-883064R02 JULY 2006 Page 6C-25

Bigfoot Gear Housing

Upper Driveshaft Bearing

1. Replace the upper driveshaft bearing and sleeve if either are rust stained, or if bearing
will not roll freely. Remove the bearing, and then the sleeve using a puller assembly with
suitable jaws.

c
a

b 19177

a - Upper driveshaft bearing

b - Sleeve
c - Puller assembly
Puller Assembly 91-83165T

IMPORTANT: The upper driveshaft bearing/sleeve must be removed prior to oil

sleeve removal.

Page 6C-26 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Oil Sleeve
1. Remove the oil sleeve, if necessary, using the puller assembly with suitable jaws.

b
a

19222

a - Oil sleeve
b - Puller assembly
Puller Assembly 91-83165T

90-883064R02 JULY 2006 Page 6C-27

Bigfoot Gear Housing

Lower Driveshaft Bearing Race

IMPORTANT: The upper driveshaft bearing/sleeve and oil sleeve do not have to be
removed for lower driveshaft bearing race removal.
IMPORTANT: Retain shims for reassembly.
1. Remove the bearing race and shims using the bearing race tool.

19171

a - Bearing race
b - Shims
c - Bearing race tool
Bearing Race Tool 91-14308T02

Page 6C-28 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Shift Shaft

1. Remove the shift shaft bushing screws.

53926

a - Screw (M6 x 1) (2)

NOTE: Remove rough edges from the shift shaft splines before removing the shift shaft
bushing.
2. Remove the shift shaft bushing, and shift shaft.

a b

53927

a - Bushing
b - Shift shaft

90-883064R02 JULY 2006 Page 6C-29

Bigfoot Gear Housing

3. Remove the shift shaft cam from the housing.

4. Replace shift cam if worn.

51117

a - Shift shaft cam (number down)

5. Remove the shift shaft bushing and clip from the shift shaft.
6. Replace the shift shaft if splines are worn, or if shaft is twisted.
7. Remove and discard the O-ring.
a
d c e d
b

53928

a - Bushing
b - Clip
c - Shift shaft
d - Splines
e - O-ring

8. Remove and discard the seal.

a
53929

a - Seal

Page 6C-30 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Forward Gear Bearing Race

IMPORTANT: Retain shims for reassembly. If the shims are damaged, replace with
new shims of equal thickness.
1. Remove the race and shims using a slide hammer.

c
b 27653

a - Race
b - Shims
c - Slide hammer
Slide Hammer 91-34569A1

Reassembly
Forward Gear Bearing Race
NOTE: Propeller shaft should be vertical when installing the bearing race.
1. Place the shims retained from the disassembly into the housing. If the shims were lost,
or a new gear housing is being assembled, start with 0.254 mm (0.010 in.) shims.
2. Assemble the components as shown using a mandrel. Apply 2-4-C Marine Lubricant
with Teflon to the O.D. of the race. Use an appropriate mandrel to drive the race into the
housing. Install the propeller shaft and bearing carrier into the gear housing.
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

90-883064R02 JULY 2006 Page 6C-31

Bigfoot Gear Housing

3. Install a propeller nut on the end of the driveshaft. Strike the propeller shaft end with a
lead hammer until the bearing race is seated in the gear housing.
NOTE: Install a nut on the end of the propeller shaft to prevent damage to the propeller shaft
threads.
e d

95
b
19179

a - Shims d - Disassembled propeller shaft

b - Race e - Assembled bearing carrier
c - Mandrel
Mandrel 91-31106T

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

Shift Shaft
1. Apply Loctite 271 Threadlocker on the O.D. of the new seal.
2. Press the seal into the shift shaft bushing until the seal is seated against the shoulder.
3. Install a new O-ring.
4. Apply 2-4-C Marine Lubricant with Teflon on the O-ring and the I.D. of the seal.
a
7

c b
95
53930

a - Seal
b - Bushing
c - O-ring
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

7 Loctite 271 Threadlocker 92-809819 92-809819

Page 6C-32 90-883064R02 JULY 2006

 Bigfoot Gear Housing

5. Assemble the components as shown.

a b

c
53928

a - Shift shaft
b - E clip
c - Shift shaft bushing

6. Install the shift cam with numbers down. Align the hole in the shift cam with the shift shaft
pilot bore in the gear housing.

51117

a - Shift cam - Numbers down

b - Shift shaft pilot bore

7. Install shift shaft assembly. Insert splines into shift cam.

53932

a - Shift shaft assembly

b - Splines

90-883064R02 JULY 2006 Page 6C-33

Bigfoot Gear Housing

8. Apply Loctite 271 Threadlocker to the bottom half of the threads on each screw. Install
the screws and tighten to the specified torque.

53926

a - Screw (2)
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

Description Nm lb. in. lb. ft.

Screw 7 60

Page 6C-34 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Bearing Carrier Reassembly

1. Lubricate the O.D. of the bearing and bearing carrier bore with 2-4-C Marine Lubricant
with Teflon.
2. Protect the lip on the forward side of the bearing carrier, using the bearing installation
tool.
3. Press the propeller shaft needle bearing, number side toward the mandrel, into the
carrier until the bearing bottoms out.

95

21042

a - Bearing installation tool

b - Mandrel
c - Suitable driver rod
Bearing Installation Tool 91-13945
Mandrel 91-15755T

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

4. Place the smaller diameter seal on the longer shoulder of the oil seal driver with the seal
lip away from the shoulder.

90-883064R02 JULY 2006 Page 6C-35

Bigfoot Gear Housing

5. Protect lip on the front side of the bearing carrier using the bearing installation tool. Apply
Loctite 271 Threadlocker on the O.D. of the seal. Press the seal into the carrier until the
tool bottoms out.

a 7
b

21040
a - Seal
b - Oil seal driver
c - Bearing installation tool
Bearing Installation Tool 91-13945
Oil seal driver 91-31108T
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

6. Place the larger diameter seal on the shorter shoulder of the oil seal driver with the seal
lip toward the shoulder.
7. Protect lip on the front side of the bearing carrier using the bearing installation tool. Apply
Loctite 271 Threadlocker on the O.D. of the new seal. Press the seal into the carrier until
the tool bottoms out.

a
b

21041

a - Seal
b - Oil seal driver
c - Bearing installation tool
Bearing installation tool 91-13945
Oil seal driver 91-31108T
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

Page 6C-36 90-883064R02 JULY 2006

 Bigfoot Gear Housing

8. Install the O-ring. Lubricate the O-ring, and propeller shaft seal lips with 2-4-C Marine
Lubricant with Teflon.
9. Lubricate the O.D. of the reverse gear bearing, and the bearing carrier bore with a light
coating of 2-4-C Marine Lubricant with Teflon.
10. Press the bearing into the carrier until the tool bottoms.

95

c
a

19163
a - O-ring
b - Bearing - Numbered side toward tool
c - Bearing installation tool
Bearing Installation Tool 91-13945
Oil Seal Driver 91-31108T

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

11. Install the thrust washer. Coat the thrust washer with Premium Gear Lubricant.

82

19167
a - Thrust washer
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lube 92-802846A1 92-802846Q1

90-883064R02 JULY 2006 Page 6C-37

Bigfoot Gear Housing

12. Install the thrust bearing. Coat the thrust bearing with Premium Gear Lubricant.

82

19168

a - Thrust bearing
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lube 92-802846A1 92-802846Q1

13. Apply Premium Gear Lubricant to the bearing surface of the reverse gear, and install the
reverse gear.

82

19202

a - Reverse gear
b - Bearing surface
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lube 92-802846A1 92-802846Q1

Page 6C-38 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Forward Gear Reassembly

1. Apply 2-4-C Marine Lubricant with Teflon to the I.D. of the bearing. Press only on the
inner race of bearing onto the gear using a suitable mandrel. Because the gear hub is
longer than the bearing, a tube type mandrel should be used to install the bearing. This
will allow the bearing to bottom out on the gear.

95
a

51869

a - Mandrel
b - Bearing
Mandrel 91-37350T

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

2. Inspect the reverse gear end of the clutch to determine the number of jaws.

c
a 56784

6 Jaw Reverse Clutch

a - Stamped “6”
b - Numbered end of needle bearing
c - 6 jaw reverse clutch

90-883064R02 JULY 2006 Page 6C-39

Bigfoot Gear Housing

3. Apply Premium Gear Lubricant to the I.D. of the forward gear, and the O.D. of the
needle bearing. Press the needle bearing into the forward gear until the tool bottoms
out on the gear.

a
82
b

a - Bearing installation tool

b - Needle bearing - numbered side toward installer tool
Bearing Installation Tool 91-877321A1

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lube 92-802846A1 92-802846Q1

4. Install the retaining ring into the groove of the forward gear by starting at one end of the
retaining ring, and working it around until seated in the groove.
a

57905

a - Retaining ring
b - Groove in forward gear

Page 6C-40 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Propeller Shaft Reassembly

1. Install the components into the propeller shaft in the sequence shown.
NOTE: When installing the clutch, ensure the ratcheting angled clutch teeth are toward the
forward gear, and the square non-ratcheting clutch teeth are toward the reverse gear.

e f g
b

95

d c a 51265

Assembly Sequence
a - Spring
b - Guide block
c - Clutch
d - Three metal balls
e - Cam follower
f - Forward clutch teeth
g - Reverse clutch teeth
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

2. Align the hole in the clutch with the hole in the guide block; install the cross pin.

b
a

51800

a - Apply pressure in this direction

b - Cross pin

90-883064R02 JULY 2006 Page 6C-41

Bigfoot Gear Housing

3. Install the spring. Do not allow the spring coils to overlap each other.

51876
a - Spring

Driveshaft Wear Sleeve Installation

1. Install a new rubber ring.
2. Apply a light coat of Loctite 271 Threadlocker on the O.D. of the rubber ring.
a

19152

a - Ring
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

3. Insert sleeve into the holder.

19169

a - Sleeve
b - Holder

Page 6C-42 90-883064R02 JULY 2006

 Bigfoot Gear Housing

4. Press sleeve onto the driveshaft using the wear sleeve installation tool. Continue
pressing until the upper and lower part of the tool make surface to surface contact.
5. Remove excess Loctite from the assembled shaft.

a
b d

19166

a - Driveshaft
b - Wear sleeve installation tool
c - Upper part of tool
d - Lower part of tool
Wear Sleeve Installation Tool 91-14310T1

90-883064R02 JULY 2006 Page 6C-43

Bigfoot Gear Housing

Driveshaft Lower Bearing Race Installation

1. Lubricate the O.D. of the bearing race with 2-4-C Marine Lubricant with Teflon.
2. Install shims and bearing race into the housing. If shims were lost, or a new gear housing
is being assembled, start with 0.635 mm (0.025 in.) shims.

f e

b
95

c 58207

a - Shims - Retained from disassembly

b - Bearing race
c - Mandrel
d - Mandrel
e - Threaded rod
f - Nut
Bearing Installation Tool 91-14309T02
Mandrel 13780 (NLA)
Mandrel 13781 (NLA)
Puller Kit 91-31229A7
Threaded Rod and Nut 91-31229 and 91-24156

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

NOTE: Mandrels 91-13780 and 91-13781 are contained in Bearing Installation Tool
91-14309T02.
NOTE: Threaded rod and nut are contained in Puller Kit 91-31229A7.

Page 6C-44 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Oil Sleeve Installation

1. Install oil sleeve with tab positioned as shown.

53934

a - Oil sleeve
b - Tab

Driveshaft Upper Bearing Installation

1. Lubricate the I.D. of the bearing sleeve and the O.D. of the bearing with 2-4-C Marine
Lubricant with Teflon.
2. Press the bearing into the sleeve using a mandrel from the bearing installation tool.

d
c
95 a
b

19164

a - Bearing sleeve
b - Tapered end
c - Bearing - Numbered side toward mandrel
d - Mandrel
Bearing installation tool 91-14309T02
Mandrel 13781 (NLA)

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

NOTE: Mandrel 91-13781 is contained in Bearing Installation Tool 91-14309T02.

90-883064R02 JULY 2006 Page 6C-45

Bigfoot Gear Housing

3. Install bearing/sleeve into the housing.

IMPORTANT: Oil sleeve must be installed prior to upper driveshaft bearing
installation.
IMPORTANT: Lower driveshaft bearing cup pilots mandrel during installation of the
upper driveshaft bearing/sleeve. Lower bearing cup must be installed prior to
installing upper bearing/sleeve.
Lower Driveshaft Bearing Cup Pilots Mandrel 91-13780

f
c

58206
d
a - Bearing/sleeve
b - Tapered end of sleeve
c - Mandrel
d - Mandrel
e - Threaded rod
f - Nut
Bearing Installation Tool 91-14309T02
Mandrel 13780 (NLA)
Mandrel 13781 (NLA)
Puller Kit 91-31229A7
Threaded Rod and Nut 91-31229 and 91-24156

NOTE: Mandrels 91-13780 and 91-13781 are contained in Bearing Installation Tool
91-14309T02.
NOTE: Threaded rod and nut are contained in Puller Kit 91-31229A7.

Page 6C-46 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Forward Gear, Driveshaft Lower Bearing, Pinion Gear, and Driveshaft

Installation
1. Lubricate the forward gear roller bearings with Premium Gear Lubricant.
2. Install the forward gear assembly into the forward bearing race.
3. Clean the driveshaft pinion nut threads with Loctite Primer or a suitable degreaser.
4. Lubricate the pinion roller bearings with Premium Gear Lubricant.
5. Install the pinion bearing and pinion gear into the gearcase.
6. Install the driveshaft into the gearcase, pinion bearing and pinion gear.
7. Install the original pinion nut. Do not install a new pinion nut until the gear backlash
is correct.
8. Use a driveshaft holding tool and torque the pinion nut to specification.

d
e

b
82

c
f
a 7
19175

Assembly Sequence:
a - Forward gear assembly.
b - Driveshaft lower tapered roller bearing
c - Pinion gear
d - Driveshaft
e - Driveshaft holding tool
f - Pinion nut
Driveshaft Holding Tool 91-56775T

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lubricant 92-802846A1 92-802846Q1

7 Loctite 271 Threadlocker 92-809819 92-809819

Description Nm lb. in. lb. ft.

Pinion nut 95 70

90-883064R02 JULY 2006 Page 6C-47

Bigfoot Gear Housing

Pinion Gear Depth and Forward Gear Backlash

DETERMINING PINION GEAR DEPTH
NOTE: Read the entire procedure before attempting any change in shim thickness.
IMPORTANT: Forward gear assembly pilots the end of the pinion gauge and must be
installed in the gear housing when checking pinion gear depth. Without it an
inaccurate measurement will be obtained.
1. Clean the gear housing bearing carrier shoulder and diameter.
2. With the gear housing positioned with the driveshaft vertical, install the bearing tool over
the driveshaft in the sequence shown. Ensure the bearing preload tool nut is completely
threaded on the bolt.
3. Lock the bolt to the driveshaft with the two set screws.

g
h h

e c

f b

a
d

a - Adapter
b - Thrust bearing
c - Thrust washer
d - Spring
e - Nut
f - Bolt
g - Sleeve
h - Set screw (2)
Bearing Preload Tool 91-14311A04

4. Measure the distance between the top of the nut and the bottom of the bolt head.
5. Increase the distance by 25.4 mm (1 in.).
6. Rotate the driveshaft 5 - 10 revolutions. This should properly seat the driveshaft tapered
roller bearing.

c
a
b

19884

a - 25.4 mm (1 in.) c - Bolt head

b - Nut

Page 6C-48 90-883064R02 JULY 2006

 Bigfoot Gear Housing

7. Assemble the pinion gear locating tool as shown. Do not tighten the collar retaining
screw at this time. Install gauging block with numbers away from the split collar.

b d e

f
a c

a - Arbor d - Split collar

b - Gauging block e - Collar retaining screw
c - Screw (2) f - Snap ring
Pinion Gear Locating Tool 91-12349A05

8. Insert the tool into the forward gear assembly. Position the gauging block under the
pinion gear as shown.

22067

a - Gauging block

9. Remove the tool, taking care not to change the gauging block position, and tighten the
collar retaining bolt.
10. Insert the tool into the forward gear assembly. Position the proper numbered flat (from
chart) of the gauging block under the pinion gear.

Gear ratio (Pinion gear

Model Flat number Disc number
teeth/Reverse gear teeth)
30/40 Bigfoot (4-Stroke) 2.31:1 (13/30) 8 3

90-883064R02 JULY 2006 Page 6C-49

Bigfoot Gear Housing

11. Install the locating disc against the bearing carrier shoulder in the gear housing.
12. Position access hole as shown.

Disc 3
b

24643

a - Locating disc
b - Access hole

13. Determine the pinion gear depth by inserting a feeler gauge through the access hole in
the locating disc.
14. The correct clearance between the gauging block and pinion gear is 0.64 mm (0.025 in.).
15. If the clearance is correct, leave the bearing preload tool on the driveshaft and proceed
to Determining Forward Gear Backlash.
16. If the pinion clearance is more than 0.064 mm (0.025 in.) remove shims under the pinion
bearing race. If clearance is less than 0.064 mm (0.025 in.) add shims behind the pinion
bearing race.
c
a

7 b

24643

a - Feeler gauge
b - Gauging block
c - Pinion gear
d - Bearing race
Bearing Preload Tool 91-14311A04

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

Page 6C-50 90-883064R02 JULY 2006

 Bigfoot Gear Housing

DETERMINING FORWARD GEAR BACKLASH

NOTE: Read the entire procedure before attempting any change in shim thickness.
1. To obtain correct forward gear backlash, the pinion gear depth must be correctly set first.
Refer to Determining Pinion Gear Depth.
2. Install the bearing preload tool on the driveshaft if not installed. Refer to Determining
Pinion Gear Depth.
3. Install the bearing carrier and the propeller shaft assembly into the gearcase.
4. Secure the bearing carrier to the gearcase with the bearing carrier retaining bolts. Bolts
do not need to be torqued.
5. Install puller components as shown.
6. Holding the driveshaft to prevent from turning, torque the puller bolt to the specified
torque.
7. Rotate driveshaft 5 - 10 revolutions. This should properly seat the forward gear tapered
roller bearing.
8. Retorque puller bolt to the specified torque.

a b
d

53936

a - Propeller shaft
b - Bearing carrier
c - Puller jaws
d - Puller bolt
Bearing Preload Tool 91-14311A04
Puller Jaws 91-46086A1
Puller Bolt 91-85716

Description Nm lb. in. lb. ft.

Puller bolt 5 45

90-883064R02 JULY 2006 Page 6C-51

Bigfoot Gear Housing

9. Install components as shown to check backlash.

a

b
c d

f 51117

a - Dial indicator
b - Backlash indicator tool
c - Dial indicator adapter kit
d - Nuts (2)
e - Threaded rod - Obtain locally
f - Nuts and washers (2)
Backlash Indicator Tool 91-78473
Dial Indicator 91-58222A1
Dial Indicator Adapter Kit 91-83155
Threaded Rod Obtain locally

10. Position the dial indicator on line 4 of the backlash indicator tool. Ensure the dial indicator
is perpendicular to the indicator tool.
11. Hold the propeller shaft and lightly turn the driveshaft back and forth. No movement
should be noticed at the propeller shaft.
12. The dial indicator displays the amount of backlash in thousandths. Ensure the amount
of backlash is within specifications.

Backlash specification
Minimum 0.30 mm (0.012 in.)
Maximum 0.48 mm (0.019 in.)

13. If backlash is less than the minimum specification, add shims behind the forward gear
bearing race. If backlash is more than the maximum specification, remove shims in front
of the forward gear bearing race.
NOTE: By adding or subtracting 0.025 mm (0.001 in.) shim, the backlash will change
approximately 0.025 mm (0.001 in.).
14. When the backlash is to specification, remove the original pinion nut and install a new
pinion nut. Apply Loctite 271 Threadlocker to the pinion nut threads and torque to
specification.
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

Description Nm lb. in. lb. ft.

Pinion nut 95 70

Page 6C-52 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Bearing Carrier and Propeller Shaft Installation

1. Insert the propeller shaft assembly into the bearing carrier.
2. Before installing the bearing carrier assembly into the gear housing, obtain locally a
152.4 mm (6 in.) long by 31.7 - 38.1 mm (1-1/4 in. - 1-1/2 in.) diameter piece of PVC pipe.
Install the PVC pipe over the propeller shaft, and secure the pipe against the bearing
carrier assembly with the propeller nut and tab washer. This holds the reverse gear and
thrust bearing tight against the bearing carrier preventing possible bearing damage
during installation.

a b
c
d

e 21043

a - Bearing carrier assembly

b - PVC pipe
c - Propeller nut
d - Propeller shaft
e - Tab washer

90-883064R02 JULY 2006 Page 6C-53

Bigfoot Gear Housing

3. Generously lubricate O-ring, bearing carrier, and gear housing mating surfaces with
2-4-C Marine Lubricant with Teflon.
4. Install bearing carrier and propeller shaft into the housing with the word “TOP” toward
top of the housing.
5. Install the bearing carrier fasteners, and tighten to the specified torque.

a b

95
21044

a - O-ring
b - “TOP”
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

NOTE: Use thick 2.29 mm (0.090 in.) washers (12-855941) under fasteners if not previously
installed.

Washer thickness Nm lb. in. lb. ft.

2.29 mm (0.090 in.) 30 22
1.53 mm (0.060 in.) 34 25

a
b

a - Washers
b - Fasteners

Page 6C-54 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Water Pump Reassembly and Installation

1. Place the water pump base upper seal on the long shoulder of the oil seal driver, with
the seal lip away from the shoulder.
2. Apply Loctite 271 Threadlocker on the O.D. of the seal. Press the seal into the water
pump base until the tool bottoms out.

7
b

51553

a - Seal - lip faces up (water pump base installed on gearcase)

b - Spring - faces up (water pump base installed on gearcase)
c - Oil seal driver
d - Long shoulder of oil seal driver
e - Short shoulder of oil seal driver
Oil Seal Driver 91-13949

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

90-883064R02 JULY 2006 Page 6C-55

Bigfoot Gear Housing

3. Place the water pump base lower seal on the short shoulder of the oil seal drive with the
seal lip toward the shoulder.
4. Apply Loctite 271 Threadlocker on the O.D. of the seal. Press seal into the water pump
base until the tool bottoms.
5. Lubricate lip of each seal with 2-4-C Marine Lubricant with Teflon.

95

7 b 51553

a - Seal - lip faces down (water pump base installed on gearcase)

b - Spring - faces down (water pump base installed on gearcase)
c - Oil seal driver
d - Long shoulder of oil seal driver
e - Short shoulder of oil seal driver
Oil Seal Driver 91-13949

Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

7 Loctite 271 Threadlocker 92-809819 92-809819

6. Install gasket.

19218

a - Gasket

Page 6C-56 90-883064R02 JULY 2006

 Bigfoot Gear Housing

IMPORTANT: To prevent cutting the seal lips, remove any burrs or sharp edges from
the driveshaft splines before installing the water pump base assembly.
7. Install components as shown. Apply Loctite 271 Threadlocker on the bottom half of the
screw threads, and tighten to the specified torque (in sequence shown).
a 3 1 5
b

2
6
4 19217
a - Water pump base
b - Screw (M6 x 1) and washers - 6 each
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

Description Nm lb. in. lb. ft.

Screw 6.8 60

8. Install gasket and plate.

19219
a - Gasket
b - Plate

9. Install gasket, drive key, and impeller.

b
a

19220
a - Gasket
b - Drive key
c - Impeller

90-883064R02 JULY 2006 Page 6C-57

Bigfoot Gear Housing

10. Lubricate the I.D. of the cover with 2-4-C Marine Lubricant with Teflon.
11. Rotate the driveshaft clockwise, and push the impeller housing down over the impeller
until it contacts the water pump base.
12. Apply Loctite 271 Threadlocker to the bottom threads of the cover screws. Install the
cover screws and tighten to the specified torque.

95 a b

19212

a - Impeller housing
b - Screw (M6 x 30) (4)
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

7 Loctite 271 Threadlocker 92-809819 92-809819

Description Nm lb. in. lb. ft.

Cover screws 6.8 60

Gear Housing Pressure Test

1. Remove the vent plug, and install the pressure test gauge.

2. Pressurize the housing to 69 - 83 kPa (10 - 12 psi), and observe the gauge for five
minutes.

Gearcase test pressure

Applied air pressure 69 - 83 kPa (10 - 12 psi)
Length of time Five minutes

Page 6C-58 90-883064R02 JULY 2006

 Bigfoot Gear Housing

3. Rotate driveshaft, propeller shaft, and shift shaft while the housing is pressurized to
check for leaks.

4. If pressure drop is noted, immerse the housing in water.

5. Repressurize to 69 - 83 kPa (10 - 12 psi), and check for air bubbles.

Gearcase test pressure

Applied air pressure 69 - 83 kPa (10 - 12 psi)
Length of time Five minutes

6. Replace the leaking seals as necessary. Retest the housing.

NOTE: The gearcase should hold 69 - 83 kPa (10 - 12 psi) for five minutes.
7. Remove the tester from the housing and install the vent plug, and the sealing washer.
Tighten to the specified torque.

Description Nm lb. in. lb. ft.

Vent screw 6.8 60

90-883064R02 JULY 2006 Page 6C-59

Bigfoot Gear Housing

Filling Gear Housing With Lubricant

NOTE: The gear housing lubricant capacity is 710 ml (24 fl. oz.).

WARNING
If a gear housing is installed on an outboard, to avoid accidental starting,
disconnect and isolate the spark plug leads from the spark plugs before working
near the propeller.

CAUTION
Do not use automotive grease in the gear housing. Use only Premium Gear Lubricant.

1. Remove any gasket material from the fill/drain and vent screws, and the gear housing.
2. Install a new sealing washer on the fill/drain and vent screws.
IMPORTANT: Never add lubricant to the gear housing without first removing the vent
screws or the gear housing cannot be filled because of trapped air. Fill the gear
housing only when the driveshaft is in a vertical position.
3. Remove lubricant fill/drain screw and sealing washer from the gear housing.
4. Insert lubricant tube into the fill hole, then remove vent screws and sealing washer.
5. Fill the gear housing with lubricant until excess starts to flow out of one of the vent screw holes.
6. Install this vent screw and sealing washer only and tighten to the specified torque.
Continue filling until excess starts to flow out of a second vent screw hole.
7. Rotate driveshaft clockwise approximately 10 revolutions. Let the gearcase sit for at
least one minute to allow any trapped air to settle out, then top off lubricant level.

a c

b
53922

a - Vent screw
b - Fill/drain screw
c - Oil level vent screw
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

82 Premium Gear Lube 92-802846A1 92-802846Q1

8. Install second vent screw and sealing washer. Tighten to the specified torque.
IMPORTANT: Do not lose more than 30 cc (1 fl. oz.) of gear lubricant while reinstalling
the fill/drain screw.
9. Remove lubricant tube, and install fill/drain screw and sealing washer. Tighten to the
specified torque.
Description Nm lb. in. lb. ft.
Fill/drain and vent screw 6.8 60

Page 6C-60 90-883064R02 JULY 2006

 Bigfoot Gear Housing

Gearcase Installation
WARNING
Disconnect and isolate the spark plug leads from the spark plugs before installing
the gear housing onto the driveshaft housing. Failure to follow this warning could
result in accidental engine starting, and possible injury.
1. Position the outboard shift linkage into the forward gear position.

a
Remote Control Model Shown
a - Shift lever

2. Tilt engine to the full up position. Engage the tilt lock lever.
3. Shift gear housing into neutral position. Propeller shaft will rotate freely in either direction.
4. Install the water tube seal. Apply 2-4-C Marine Lubricant with Teflon to the I.D. of the
seal.
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

90-883064R02 JULY 2006 Page 6C-61

Bigfoot Gear Housing

5. Apply a bead of RTV Silicone Sealer as shown.

NOTE: For ease of gear housing installation, install the water tube seal (labyrinth end) onto
the water tube in the driveshaft housing. Tapered end of the water tube seal goes onto the
water pump.
95

116
b
53938

a - Water tube seal

b - RTV silicone sealer
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon
Loctite 587 Ultra Blue RTV
116 92-809825 92-809825
Silicone Sealer

Page 6C-62 90-883064R02 JULY 2006

 Bigfoot Gear Housing

CAUTION
Do not lubricate top of driveshaft. Excess lubricant will not allow driveshaft to fully
engage crankshaft. Tightening the gear housing fasteners (if excess lubricant is on
top of the driveshaft) will load the driveshaft/crankshaft and may damage either or
both powerhead and gear housing. Wipe the top of the driveshaft free of lubricant.

6. Apply a light coat of 2-4-C Marine Lubricant with Teflon onto the driveshaft splines.
7. Apply a light coat of 2-4-C Marine Lubricant with Teflon on the gearcase shift shaft
splines and upper shift shaft splines. Do not use lubricant on ends of the shift shafts.

a - Nylon spacer
b - Shift shaft coupler
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

7 Loctite 271 Threadlocker 92-809819 92-809819

8. Shift gear housing into forward gear. Forward gear will ratchet when the propeller shaft
is turned clockwise. Resistance will be felt when the propeller shaft is rotated
counterclockwise.
9. Apply Loctite 271 Threadlocker on the threads of the gear housing retaining screws.
NOTE: It may be necessary to move the shift block under the cowl slightly, to align upper
shift shaft splines with shift shaft coupler splines, during the installation of the gear housing.
10. Move gear housing up toward the driveshaft housing, while aligning upper shift shaft
splines with shift shaft coupler splines, water tube with water tube seal, and crankshaft
splines with driveshaft splines.
11. Install four fasteners and washers. Install locknut and washer.

90-883064R02 JULY 2006 Page 6C-63

Bigfoot Gear Housing

12. Torque bolts and locknut (or nuts only where applicable) to the specified torque.

b a 7

53922

a - Fasteners and washers (2 Each Side)

b - Locknut and washer
Tube Ref.
Description Mercury Part Number Quicksilver Part Number
No.

7 Loctite 271 Threadlocker 92-809819 92-809819

Description Nm lb. in. lb. ft.

Screw or nut 54 40

13. Check shift operation as follows:

• Place the shift lever in forward gear. Gear housing should ratchet when the propeller
shaft is turned clockwise. Resistance should be felt when the propeller shaft is
turned counterclockwise.
• Place the shift lever in neutral. Propeller shaft should rotate freely in either direction.
• While rotating propeller shaft, place the shift lever in reverse gear. Resistance
should be felt when the propeller shaft is rotated in either direction.
IMPORTANT: If shift operation is not as described above, the gear housing must be
removed, and the cause of the problem corrected.

Trim Tab Adjustment and Replacement

IMPORTANT: The trim tab is now painted and does not aid in protecting the driveshaft
housing and gear housing from galvanic corrosion. Side anodes now provide protec-
tion. Do not paint or place protective coating on the side anodes, or corrosion protec-
tion function will be lost.

TRIM TAB REPLACEMENT

1. Replace trim tab if damaged. Mark the location of the old trim tab on the anti-ventilation
plate before removal. Install a new trim tab in the same location.

TRIM TAB ADJUSTMENT

NOTE: The trim tab provides a means to balance some of the steering load that is caused
by propeller torque at higher operating speeds.

Page 6C-64 90-883064R02 JULY 2006

 Bigfoot Gear Housing

NOTE: Loosen trim tab bolt sufficiently to allow the trim tab to disengage from the locking
ridges in the gearcase before attempting to move the tab. Do not strike the trim tab with a
hard object to make adjustments.
1. Shift engine control into neutral and turn the ignition key to the “OFF” position.
2. If at higher speeds the boat turns more easily to the left, loosen screw, move the trim
tab trailing edge to the left when viewed from behind. Tighten retaining screw to the
specified torque.
3. If the boat turns more easily to the right, loosen screw, move the trim tab trailing edge
to the right when viewed from behind. Tighten retaining screw to the specified torque.
c

b a 53931

a - Trim tab
b - Anti-ventilation plate
c - Retaining screw and washer
Description Nm lb. in. lb. ft.
Retaining screw 29.8 22

90-883064R02 JULY 2006 Page 6C-65

 Throttle/Shift Linkage

Attachments/Control Linkage
Section 7A - Throttle/Shift Linkage
Table of Contents
Linkage (Non Bigfoot) . . . . . . . . . . . . . . . . . . . . 7A-3 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-7
Linkage (Bigfoot) . . . . . . . . . . . . . . . . . . . . . . . . 7A-5 Maximum Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-8
Throttle Link Adjustment . . . . . . . . . . . . . . . . . 7A-7

7
A

90-883064R02 JULY 2006 Page 7A-1

Throttle/Shift Linkage

Linkage (Non Bigfoot)

Page 7A-2 90-883064R02 JULY 2006

 Throttle/Shift Linkage

Linkage (Non Bigfoot)

Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
1 1 Screw (M8 x 70) 11.3 100
2 1 Screw (M6 x 60)
3 1 Nut
4 1 Throttle lever
5 1 Retainer (Non handle)
6 2 Screw (M6 x 40) 8.5 75
7 1 Cap
8 1 Throttle arm
9 1 Throttle cam
10 1 Bushing
11 1 Screw (10-16 x 0.625) Drive tight
12 1 Bushing
13 1 Bracket (Non handle)
14 1 Latch (Non handle)
15 2 Screw (M6 x 16) (Non handle) 8.5 75
16 2 Sleeve (Non handle)
17 1 Shift rod (Non handle)
18 1 Retainer (Non handle)
19 1 Shift lever (Non handle)
20 1 Bushing
21 1 Throttle link
22 1 Socket
23 1 Horizontal shift shaft
24 1 Retainer
25 1 Washer
26 1 Cotter pin
27 1 Spring
28 2 Spring
29 1 Plate
30 2 Screw (M5 x 16) 5 45
31 1 Switch (Electric handle models)
32 2 Screw (M3 x 20) (Electric handle models) 2 20
33 1 Plate - switch (Electric handle models)

Tube Ref. Description Mercury Part Number Quicksilver Part

No. Number
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

66 Loctite 242 92-809821 92-809821

90-883064R02 JULY 2006 Page 7A-3

Throttle/Shift Linkage

Linkage (Bigfoot)

Page 7A-4 90-883064R02 JULY 2006

 Throttle/Shift Linkage

Linkage (Bigfoot)
Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
1 1 Screw (M8 x 70) 11.3 100
2 1 Screw (M6 x 60)
3 1 Nut
4 1 Throttle lever
5 1 Retainer
6 2 Screw (M6 x 40) 8.5 75
7 1 Cap
8 1 Throttle arm
9 1 Throttle cam
10 1 Bushing
11 1 Screw (10-16 x 0.625) Drive tight
12 1 Bushing
13 1 Bracket
14 1 Latch
15 2 Screw (M6 x 16) 8.5 75
16 2 Sleeve
17 1 Shift rod
18 1 Retainer
19 1 Shift lever
20 1 Bushing
21 1 Throttle link
22 1 Socket
23 1 Shift link
24 2 Nyliner
25 2 Washer
26 1 Nut
27 1 Cotter pin
28 1 Shift shaft lever
29 1 Bushing
30 1 Guide - shift rod

Tube Ref. Description Mercury Part Number Quicksilver Part

No. Number
2-4-C Marine Lubricant with 92-802859A1 92-802859Q1
95
Teflon

90-883064R02 JULY 2006 Page 7A-5

Throttle/Shift Linkage

Throttle Link Adjustment

Adjustment
NOTE: For remote control models, remove remote control throttle cable during throttle link
adjustment. For tiller handle models, throttle cables remain attached, and throttle twist grip
should be used to advance throttle during throttle link adjustment.
1. Lightly hold the throttle body arm against the idle stop.
2. Slowly push the throttle lever forward until you feel the throttle body start to move. The
center of the throttle arm timing mark should line up with the throttle cam timing mark.
3. Remove the lower cowl. Refer to Section 5A - Cowl Removal.
4. Disconnect the throttle link rod from the throttle arm and throttle body arm.
5. If the throttle body arm engages, and the throttle shutter opens before the center of the
roller aligns with the throttle cam timing mark, shorten the link rod by turning the socket
clockwise. If the throttle body arm engages after the roller aligns with the throttle cam
alignment mark, lengthen the link rod by turning the socket counterclockwise.
6. Snap the socket onto the throttle body arm and push rod end into the throttle arm.
7. Repeat Steps 1 and 2. Adjust if necessary.

c d
e

a
b

d - Throttle body arm

e - Throttle lever
f - Throttle timing marks
g - Timing marks properly aligned
h - Lengthen link rod

Page 7A-6 90-883064R02 JULY 2006

 Throttle/Shift Linkage

Maximum Throttle
1. With throttle cables attached, advance the remote control handle, or throttle twist grip,
to wide open throttle position.
2. Throttle stop should lightly contact the adjoining surface. To ensure the throttle shutter
is fully open, back the throttle stop screw out until there is a gap between the throttle stop
screw and adjoining surface at wide open throttle position. Keep turning the throttle stop
screw in until the throttle stop screw contacts the adjoining surface. Turn the throttle stop
screw in one additional turn.

a - Throttle lever
b - Throttle stop screw
c - Throttle stop

90-883064R02 JULY 2006 Page 7A-7

 Tiller Handle

Attachments/Control Linkage
Section 7B - Tiller Handle
Table of Contents
Tiller Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-3 Tiller Handle Reassembly . . . . . . . . . . . . . . . . 7B-10
Tiller Handle Assembly Removal . . . . . . . . . . 7B-5 Tiller Handle Installation . . . . . . . . . . . . . . . . . . 7B-15
Tiller Handle Disassembly . . . . . . . . . . . . . . . . 7B-7 Electric Start Tiller Handle Wiring Diagram . . 7B-19
Cleaning/Inspection/Repair . . . . . . . . . . . . . . . 7B-9

7
B

90-883064R02 JULY 2006 Page 7B-1

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Notes:

Page 7B-2 90-883064R02 JULY 2006

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Tiller Handle

90-883064R02 JULY 2006 Page 7B-3

Tiller Handle

Tiller Handle
Torque
Ref.
Ref
No. Qty. Description Nm lb. in. lb. ft.
1 1 Cover kit
2 1 Pulley
3 1 Case
4 1 Screw (10-16 x 1/2 in. self-tapping) 2.3 20
5 1 Throttle cable (77.5 cm [30-1/2 in.])
6 1 Throttle cable (105 cm [41-1/2 in.])
7 1 Sleeve
8 2 Screw (M8 x 25) 15.3 135
9 1 Cover
10 1 Bushing
11 1 Arm - Steering handle
12 1 Retainer
13 1 Screw (M5 x 16) 3.9 35
14 1 Screw (M6 x 25)
15 1 Lock - Throttle
16 1 Spring
17 1 Knob - Throttle
18 1 Tiller tube
19 1 Decal
20 1 Handle - Throttle
21 1 Grip
22 1 Switch (Stop)
23 1 Shift rod
24 1 Tab washer
25 2 Screw (M10 x 90) 47.5 35
26 2 Clip
27 1 Switch (Stop)
28 1 Retainer
29 1 Bracket - Tiller
30 1 Wave washer
31 1 Bushing
32 1 Washer
33 1 Conduit
34 1 Cable tie
35 1 Decal - Shift (F-N-R)
36 1 Lanyard switch
37 1 Screw (M8 x 35) 11.3 100
38 1 Shift handle
39 1 Bushing

Tube Ref. Quicksilver Part

Description Mercury Part Number
No. Number
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

Page 7B-4 90-883064R02 JULY 2006

 Tiller Handle

Tiller Handle Assembly Removal

1. Remove the lower cowl.

a - Screws (M6 x 30) (6)

b - Screw (M6 x 60)

2. Remove the shift handle.

a - Shift handle
b - Bushing
c - Screw (M8 x 35)

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Tiller Handle

3. Loosen the jam nuts, and disconnect the throttle cables from the throttle lever.

b 58829

a - Throttle cable - Long

b - Throttle cable - Short

4. Disconnect the tiller handle wiring.

5. Remove two screws securing the tiller handle. Remove the tiller handle assembly from
the outboard.

a
BLK BLK
BLK/YEL
BLK/YEL BLK/YEL
BLK BLK

b
54272

a - Disconnect tiller handle wires

b - Screws (M10 x 90) (2)
c - Tab washer

Page 7B-6 90-883064R02 JULY 2006

 Tiller Handle

Tiller Handle Disassembly

1. Pry the two clips out of the hand grip.
2. Remove the side cover.

a - Clips (2)
b - Side cover

3. Pull the tiller arm, along with the throttle cables and wiring, from the tiller bracket.

a - Tiller arm
b - Throttle cables/wiring
c - Tiller bracket

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Tiller Handle

4. Remove the retainer and slide out the tiller tube assembly.
5. Remove the throttle friction knob assembly.

a
b

a - Retainer
b - Throttle friction knob assembly
c - Tiller tube assembly

6. Use a flat tip screwdriver to pry/push the rubber grip off the handle.

7. Pull out the stop switch harness.

a

a - Stop switch harness

8. Push the tiller tube out of the handle.

b c

b - Tiller tube
c - Handle

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 Tiller Handle

9. Remove the cover and disconnect the throttle cables from the pulley.

a - Cover
b - Throttle cables
c - Pulley

Cleaning/Inspection/Repair
1. Inspect the throttle cables for bending/damage, and replace if necessary.

2. Inspect the steering handle arm for cracks/damage, and replace if necessary.

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Tiller Handle Reassembly

1. Wrap the short throttle cable around the top groove.
2. Wrap the long throttle cable around the bottom groove.

c
b

a
a - Short throttle cable (77.5 cm [30-1/2 in.])
b - Long throttle cable (105 cm [40-1/2 in.])
c - Pulley

3. Place the pulley and cables into the case. Install cover with screw.

b c

a - Pulley
b - Cover
c - Screw (10-16 x 1/2 in.)
Description Nm lb. in. lb. ft.
Pulley cover screw 2.3 20

4. Match the tiller tube end with the slots in the handle. Pull the tube end into the handle
until it bottoms out.
5. Install the throttle friction knob components on the tiller tube.
b

a
g c
f
e
d

a - Tiller tube e - Lock

b - Handle f - Spring
c - Slots in the handle g - Knob
d - Screw (M6 x 25)

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 Tiller Handle

6. Check to make sure the tiller tube is recessed in the end of the handle 22.2 mm (7/8 in.).

a
a - 22.2 mm (7/8 in.)

7. Insert the engine stop switch harness through the tiller tube.

a - Engine stop switch harness

8. Place the stop switch into the end on the handle.

a
a - Stop switch

9. Align the grooves inside the rubber grip with the ridges on the handle. Push the rubber
grip onto the handle.
NOTE: Applying a soap/water solution to the inside of the rubber grip will ease installation.

b a
a - Rubber grip
b - Handle

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Tiller Handle

10. Place the pulley assembly into the arm.

11. Slide the tiller tube into the arm. Position the throttle friction knob into its slot.
12. Match the end of the tiller tube with the slots in the pulley assembly. Insert the tiller tube
end into the pulley assembly.
13. Secure the tiller tube with the retainer.
14. Snap the engine start switch on the tiller tube.

c
d b

a - Pulley assembly
b - Throttle friction knob
c - Retainer
d - Screw (M5 x 16)
Description Nm lb. in. lb. ft.
Tiller tube retainer screw 3.9 35

15. Place the bushing components on the arm mounts.

95
c

b
a

d
95

a - Flat washer
b - Bushing
c - Wave washer (1)
d - Bushing
Tube Ref. Quicksilver Part
Description Mercury Part Number
No. Number
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

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 Tiller Handle

16. Pull the throttle cables and wiring into the bracket.

a - Tiller bracket

17. Push the arm into the tiller bracket. Secure the arm by installing the cover and screws.
Tighten the screws to the specified torque.

c b a

a - Arm
b - Cover
c - Screw (M8 x 25) (2)
Description Nm lb. in. lb. ft.
Arm cover screw 15.3 135

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CAUTION
Wiring passing through the hand grip opening must be protected from chaffing or
being cut, by using the wiring conduit described in the following steps. Failure to
protect wiring as described could result in electrical system failure.
18. Place the throttle cables through the hand grip opening as shown.
19. Place all wiring inside the wiring conduit.
20. Route the wiring through the hand grip opening, and position the wiring conduit inside
the opening so that at least 12.7 mm (1/2 in.) extends past each end of the opening.
21. Push the wiring and throttle cables down into the handle grip, and hold in place with two
clips.

c 12.7 mm (1/2 in.)

b a
e
d

a - Hand grip opening

b - Wiring conduit
c - Wiring conduit extending 12.7 mm (1/2 in.) past the opening
d - Throttle cables
e - Clips (2)

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 Tiller Handle

Tiller Handle Installation

1. Install the tiller handle, new tab washer, and screws. Tighten the screws to the
specified torque.
2. Bend the tabs onto the flats of the screws.

c
a - Tiller handle
b - Tab washer
c - Screw (M10 x 90) (2)
Description Nm lb. in. lb. ft.
Tiller handle mounting screw 47.5 35

3. Connect the wires as shown in the wiring diagram at the end of this section.
4. Secure the wires at the connectors with a cable tie.

a - Cable tie

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5. Rotate the throttle grip to the idle position.

6. Insert the anchor on the shorter throttle cable into the anchor slot on the throttle lever.
7. Secure the cable in position by tightening the jam nuts onto the bracket, finger-tight only.
8. Insert the anchor on the remaining cable into the anchor slot on the throttle lever.
9. Secure the cable in position by tightening the jam nuts onto the bracket, finger-tight only.

e
b

58829

a - Throttle lever
b - Anchor of shorter throttle cable
c - Jam nut
d - Anchor of longer throttle cable
e - Jam nut

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 Tiller Handle

10. Rotate throttle grip to the wide open throttle position. The throttle stop screw should be
contacting the plate. If there is a gap between the throttle stop screw and plate, loosen
the jam nut on the shorter throttle cable, turn the adjustment nut clockwise. Tighten the
jam nut finger-tight, and rotate the throttle grip to full throttle. Keep adjusting until the
throttle stop screw contacts the plate. Turn the throttle stop screw one additional turn.
NOTE: No free-play should exist in the throttle grip handle once the throttle stop screw has
hit the plate. If this condition exists, readjust jam nuts on the appropriate throttle cable.

a
b

58830

a - Throttle stop screw hitting the plate

b - No free-play should exist in the throttle grip handle

IMPORTANT: After installation, cycle the throttle grip a few times from the idle posi-
tion to the wide open throttle position. Make sure the throttle stop is still contacting
the plate. If it is not, readjust the jam nuts.
11. Install the lower cowl.

a
b

a - Screw (M6 x 30) (6) c - Screw (M6 x 60)

b - Lower cowl
Description Nm lb. in. lb. ft.
Bottom cowl bolt 7 60

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Tiller Handle

12. Cables, wires, and shift rod should be routed through the grommet as shown. Seat the
grommet between the cowl halves.
f

d a
c b

e
a - Fuel connector d - Shift rod
b - Battery cables e - Tiller handle harness wires
c - Throttle cables f - Remote key harness

13. Assemble the shift rod into the shift handle by sliding the rod into the hole.

a
a - Shift rod
b - Shift handle

14. Install the shift handle assembly, bushing, and screw. Tighten the screw to the specified
torque.

95

c
b
a - Handle assembly
b - Screw (M8 x 35)
c - Bushing
Tube Ref. Quicksilver Part
Description Mercury Part Number
No. Number
2-4-C Marine Lubricant with
95 92-802859A1 92-802859Q1
Teflon

Description Nm lb. in. lb. ft.

Shift handle screw 11.3 100

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 Tiller Handle

Electric Start Tiller Handle Wiring Diagram 2005 And Prior

BLK

BLK
j

BLK

BLK
l

BLK
BLK BLK

BRN

BLK_YEL RED

GRY
o
+ –
TAN_LTBLU
PPL

YEL_RED
BLK i
m
n YEL_RED
BLK

TAN_LTBLU

YEL_RED
BLK_YEL
BLK_YEL

BLK
GRY
PPL
BLK_YEL

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 c
d
BLK_YEL

YEL_BLK
PPL

BLK

YEL_RED
TAN

RED

PPL
BLK_YEL
BLK_YEL

PPL
BLK
YEL_RED
BLK_YEL
RED

b YEL_BLK
PPL + e
–
TAN

BLK
BLK_YEL
BLK f
BLK_YEL
BLK_YEL BLK_YEL
BLK BLK g
a h
a - Ground harness below starter motor screw
b - Harness extension
c - Harness connection
d - Key switch assembly transom mount
e - Key switch
f - Horn
g - Lanyard stop switch
h - Push button stop switch
i - Battery
j - Starter motor
k - Voltage regulator/rectifier
l - Start solenoid
m - Neutral start safety switch
n - ECM
o - In-line diode

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Tiller Handle

Electric Start Tiller Handle Wiring Diagram 2006 And Newer

a - ECM
b - Voltage regulator/rectifier
c - In–line diode
d - Starter solenoid
e - Starter
f - Battery
g - Neutral start safety switch
h - 14 pin connector
i - Jumper wire (remove and discard)
j - Transom mounted key switch assembly
k - Warning horn
l - Trim harness connectors
m - Tiller handle
n - Push button stop switch
o - Lanyard stop switch
p - Trim solenoids

Page 7B-20 90-883064R02 JULY 2006

 Tiller Handle

Wire color abbreviations

BLK Black BLU Blue
BRN Brown GRY Grey
GRN Green ORN or ORG Orange
PNK Pink PPL or PUR Purple
RED Red TAN Tan
WHT White YEL Yellow
LT OR LIT Light DK or DRK Dark

90-883064R02 JULY 2006 Page 7B-21