Page 1 25 / 30 EFI & 25 EFI Jet S E RV I C E MA N U A L...
Page 3 NOTE: Indicates information that helps in the understanding of a particular step or action. 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.
Page 4 Cleanliness and Care of Product A Mercury Marine power product is a combination of many machined, honed, polished, and lapped surfaces with tolerances measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. It should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure.
Page 5 A - Gear Housing 7 - Attachments A - Throttle/Shift Linkage B - Tiller Handle 8 - Manual Starter A - Recoil Starter 9 - Jet Drive Outboard A - Jet Drive Outboard Page iii © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 7: Table Of Contents
Charging and Starting Specifications......1A-3 Propeller Chart..............1A-7 Cylinder Block/Crankcase Specifications....1A-4 25 HP 3 Cylinder EFI Propeller Information Chart..1A-7 Cooling System Specifications........1A-4 30 HP 3 Cylinder EFI Propeller Information Chart..1A-8 Piston Specifications...........1A-5 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1A-1...
Page 8: 25/30 Master Specifications
Refer to Section 1C ‑ General Information—Fuel Requirements Mechanical plunger, diaphragm Fuel pump type Electric Fuel pump pressure (mechanical) 29 kPa (4.2 psi) Fuel pump pressure (electric) 294 kPa ± 10% (42.6 psi ± 10%) Page 1A-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 9: Ignition Specifications
Above 0 °C (32 °F) 465 marine cranking amps (MCA) or 350 cold cranking amps (CCA) Below 0 °C (32 °F) 1000 marine cranking amps (MCA) or 775 cold cranking amps (CCA) 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1A-3...
Page 10: Cylinder Block/Crankcase Specifications
Thermostat Start to open temperature 60° ± 1.5 °C (140° ± 3 °F) Full open temperature 75° ± 1.5 °C (167° ± 3 °F) Valve lift 3 mm (0.12 in.) Page 1A-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 11: Piston Specifications
Oil pump side (service limit) 15.95 mm (0.628 in.) Cam lobe height (25) Intake and exhaust 23.87 mm (0.9398 in.) (25) Intake and exhaust (service limit) 23.60 mm (0.9291 in.) 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1A-5...
Page 12 0.006–0.035 mm (0.0003–0.0014 in.) Cylinder head upper camshaft bearing inside diameter 18.01–18.025 mm (0.709–0.710 in.) Oil pump camshaft bearing inside diameter 18.01–18.025 mm (0.709–0.710 in.) Valve stem seal color Intake Black Exhaust Green Page 1A-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 13: Power Trim Specifications
25 HP 3 Cylinder EFI Propeller Information Chart • Wide–open throttle RPM: 5000–6000 • Recommended transom height: 50.8–63.5 cm (20–25 in.) • Gear reduction: 1.92:1 • Right‑hand rotation (RH): standard 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1A-7...
Page 14 4.2–5.4 m 27.3–41.8 km/h Alum 48‑896892A40 (1300–2100 lb) (14–18 ft) (17‑ 26 mph) Up to 816.4+ kg 1.6–32.1 km/h 9.75 Alum 4.8+ m (17+ ft) 48‑896890A40 (1800+ lb) (1–20 mph) Page 1A-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 15 Fuse Replacement ‑ Electric Start Models......1B-6 Gearcase..............1B-21 Spark Plug Inspection and Replacement......1B-7 Positioning Outboard for Storage......1B-21 Timing Belt Inspection............1B-8 Battery Storage............1B-22 Changing Engine Oil ............1B-8 Storage Lubrication Points........1B-22 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1B-1...
Page 16: Selecting Accessories For Your Outboard
Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories.
Page 17: Epa Emissions
Check the tightness on all the fasteners—dealer item • Check the torque of the outboard mounting hardware—dealer item • Check the battery condition and tightness of the battery cable connection—dealer item 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1B-3...
Page 18: Three Years Or 300 Hours
Use a Mercury Precision or Quicksilver accessory (or equivalent) flushing attachment. IMPORTANT: The engine must be run during flushing in order to open the thermostat and circulate water through the water passages.
Page 19: Flushing Jet Models
NOTE: Jet models cannot be flushed using a flushing device. Jet models may be flushed by running the outboard in a fresh water tank. Top Cowl Removal and Installation Removal Unlock the rear latch by pulling lever up. 10190 Lift rear of cowl and disengage front hook. 10191 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1B-5...
Page 20: Installation
The electric starting circuit is protected from overload by an SFE 20 amp fuse. If the fuse is blown, the electric starter motor will not operate. Try to locate and correct the cause of the overload. If the cause is not found, the fuse may blow again. Page 1B-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 21: Spark Plug Inspection And Replacement
0.80–0.90 mm (0.031–0.035 in.) Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger‑tight, and then tighten to the specified value. Description lb‑in. lb‑ft Spark plug – 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1B-7...
Page 22: Timing Belt Inspection
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. Page 1B-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 23: Oil Filling
Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.
Page 24: Propeller Replacement
Place a block of wood between the propeller blade and the anti‑ventilation plate. Shift the outboard to neutral (N) position. NEUTRAL START 26838 10051 IMPORTANT: Refer to Spark Plug Inspection and Replacement for removing spark plug leads. Page 1B-10 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 25 NOTE: If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, then tighten the nut further to align it with the hole. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1B-11...
Page 26: Gearcase Lubrication
Gearcase Lubricant Capacity Gearcase lubricant capacity is approximately 350 ml (11.8 fl. oz.). Gearcase Lubricant Recommendation Mercury or Quicksilver Premium or High Performance Gear Lubricant. Checking Lubricant Level and Refilling Gearcase Place outboard in a vertical operating position. Remove vent plug.
Page 27: Lubrication Points
Extreme Grease 8M0071842 cable grease fitting Swivel bracket, tilt tube, transom clamp screws, steering 2-4-C with PTFE 92-802859A 1 cable grease fitting • Swivel bracket ‑ Lubricate through fitting. 10169 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1B-13...
Page 28: Jet Maintenance
The intake of gravel through the pump can round off and wear the leading edges of the impeller. Some conditions that could be experienced from a worn/dull impeller are as follows: • Noticeable performance loss, especially on acceleration • Difficulty getting the boat on plane Page 1B-14 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 29: Impeller Clearance Adjustment
"OFF" position and remove the spark plug leads from the spark plugs while servicing the impeller. Shift the outboard to the neutral position. 24835 Position the key switch or lanyard stop switch to the OFF position. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1B-15...
Page 30 Turn the nut tight on the shaft to remove any play between the impeller and shaft. If the tabs on the retainer do not line up with the flats on the nut, remove the nut and turn the retainer over and tighten the nut again. Page 1B-16 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 31: Shift Link Rod Adjustment
Adjust the shift link rod to lock the reverse gate, preventing it from interfering with water flow. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1B-17...
Page 32: Corrosion Control Anode
Fasten the anode to the flange screw. Tighten the screw to the specified torque. Install the flange screw with a new O‑ring. Tighten the flange screw to the specified torque. Flange screw O‑ring Anode Screw 57328 Description lb‑in. lb‑ft Flange screw – Screw – Page 1B-18 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 33: Lubrication Points
Swivel bracket, tilt tube, transom clamp screws, steering Extreme Grease 8M0071842 cable grease fitting Swivel bracket, tilt tube, transom clamp screws, steering 2-4-C with PTFE 92-802859A 1 cable grease fitting 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1B-19...
Page 34 Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. Lubricate the following with lightweight oil. Page 1B-20 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 35: Storage Preparation
Lubricate all outboard components listed in the Inspection and Maintenance Schedule, preceding. • Touch‑up any paint nicks. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Ref No. Description Where Used Part No.
Page 36: Battery Storage
Store the battery in a cool, dry place. • Periodically check the water level and charge the battery during storage. Storage Lubrication Points Refer to Lubrication Points in this section. Page 1B-22 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 37 Cavitation..............1C-11 Decal Application............. 1C-16 Elevation and Climate..........1C-12 Application Tips............1C-16 Detonation..............1C-12 Applying the Decal............1C-16 Propeller Selection........... 1C-12 Entrapped Air Removal..........1C-17 Following Complete Submersion........1C-12 Final Decal Squeegee..........1C-17 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1C-1...
Page 38 General Information Special Tools Cylinder Leakage Tester Snap‑On EEPV309A Aids in checking cylinder leakdown. 11604 Page 1C-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 39: Manual Start Component Identification
Recoil handle Recoil interlock cable Air vent assembly Manifold Air Temperature (MAT) sensor Silencer for Idle Air Control (IAC) Vapor Separator Tank (VST) Fuel line connector Lanyard Switch Throttle friction adjuster 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1C-3...
Page 40: 25/30 4-Stroke Efi Manual Start Starboard View
Stator voltage regulator connector Schrader valve Stator ignition/fuel charge connector Recoil interlock Timing window Manifold Absolute Pressure (MAP) sensor Intake manifold plenum Electronic Control Module (ECM) Oil level dip stick Throttle only button Page 1C-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 41: 25/30 4-Stroke Efi Manual Start Port View
Silencer for Idle Air Control (IAC) Vapor Separator Tank (VST) Recoil handle Air vent assembly Fuel cooler Water temperature sensor Ignition Coil Fuel filter Oil filter Rubber plug (optional tilt switch) 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1C-5...
Page 42: 25/30 4-Stroke Efi Manual Start Rear View
25/30 4‑Stroke EFI Manual Start Rear View Cowl latch Oil fill cap Fuel cooler Air vent assembly Recoil Interlock cable Engine lift bracket Schrader valve Fuel rail Oil level dip stick 21688 Page 1C-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 43: Electric Start Component Idenitication
Trim down solenoid Trim up solenoid Starter solenoid Air vent assembly Silencer for Idle Air Control (IAC) Vapor Separator Tank (VST) Low oil pressure lamp Fuel line connector Rubber plug 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1C-7...
Page 44: 25/30 4-Stroke Efi Electric Start Starboard View
Recoil interlock Fuse holder Voltage regulator rectifier connector Voltage regulator battery charging lead connector Recoil handle Manifold Air Pressure (MAP) sensor Intake manifold plenum Voltage regulator Oil level dip stick Page 1C-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 45: 25/30 4-Stroke Efi Electric Start Port View
Silencer for Idle Air Control (IAC) Recoil handle Vapor Separator Tank (VST) Air vent assembly Fuel cooler Water temperature sensor Power tilt switch connector Ignition coils Fuel filter Oil filter Power tilt switch 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1C-9...
Page 46: 25/30 4-Stroke Efi Electric Start Rear View
It is a known fact that weather conditions exert a profound effect on the power output of internal combustion engines. Established horsepower ratings refer to the power the engine will produce at its rated RPM under a specific combination of weather conditions. Page 1C-10 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 47: Weight Distribution (Passengers And Gear) Inside The Boat
30% relative humidity, at 25 °C (77 °F) temperature, and a barometric pressure of 29.61 inches of mercury. Summer conditions of high temperature, low barometric pressure, and high humidity all combine to reduce the engine power.
Page 48: Elevation And Climate
The boat manufacturer and the selling dealer are responsible for equipping the power package with the correct propeller. Refer to Mercury Marine's web page https://www.mercurymarine.com/en/us/propellers/selector/#/step‑one. Select a propeller that will allow the engine power package to operate at or near the top end of the recommended WOT operating RPM range with a normal load.
Page 49: Saltwater Submersion (Special Instructions)
Using Reformulated (Oxygenated) Gasoline (USA Only) Reformulated gasoline is required in certain areas of the USA and is acceptable for use in your Mercury Marine engine. The only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).
Page 50: Compression Check
IMPORTANT: When operating a Mercury Marine engine on gasoline containing methanol or ethanol, do not store the gasoline in the fuel tank for long periods. Cars normally consume these blended fuels before they can absorb enough moisture to cause trouble;...
Page 51: Analysis
Allow a minimum of one hour drying time and no more than one week before the top coat application. 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.
Page 52: Decal Removal
Lightly hinge the decal in half to expose the liner tape and remove the liner paper. Apply a little tension to the decal and squeegee the entire decal from the center towards the outside edge with overlapping strokes. Page 1C-16 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 53: Entrapped Air Removal
IMPORTANT: It is imperative to squeegee the entire decal with special attention to the edges of the decal. IMPORTANT: Do not allow the new decal to have direct sunlight contact for a minimum of 24 hours. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1C-17...
Page 55 Lifting Outboard............1D-10 Electric Fuel Pump ............ 1D-3 Determining the Mounting Height of the Outboard Jet Installing Outboard.............1D-3 ................1D-10 Mercury Marine Validated Engine Mounting Hardware Fastening the Outboard..........1D-11 ................1D-3 Steering Bracket, Steering Cable Installation... 1D-12 Installation Specifications........... 1D-3 Steering Link Rod Fasteners........
Page 56: Installation Information
Selecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for your outboard. These accessories are available from Mercury Marine dealers. IMPORTANT: Check with your dealer before installing accessories. The misuse of approved accessories or the use of nonapproved accessories can damage the product.
Page 57: Low Permeation Fuel Hose Requirement
Outboard Installation Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories. Low Permeation Fuel Hose Requirement Required for outboards manufactured for sale, sold, or offered for sale in the United States.
Page 58: Top Cowl Removal And Installation
IMPORTANT: Models not equipped with power trim or gas assist must have the transom clamps contacting the top of the transom, and the clamp screws tightened, prior to drilling the mounting bolt holes through the transom. Place outboard on center line of transom. 27005 Page 1D-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 59: Drilling Outboard Mounting Holes (Power Trim And Gas Assist)
Drilling Outboard Mounting Holes (Power Trim and Gas Assist) Use the transom drilling fixture for drilling the transom mounting holes. Drill guide holes Transom drilling fixture Transom center line 2757 Transom Drilling Fixture 91‑98234A2 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1D-5...
Page 60: Steering Bracket, Steering Cable Installation
Lubricate entire steering cable end with 2‑4‑C with PTFE. 10261 Tube Ref No. Description Where Used Part No. 2-4-C with PTFE Steering cable end 92-802859A 1 Install the steering cable seal onto the end of the tilt tube. Page 1D-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 61: Steering Link Rod Fasteners
Assemble the steering link rod onto the steering bracket with the bolt, two washers, spacer, and a locknut. Do not tighten the bolt or locknut at this time. Bolt Washer Spacer Steering bracket Locknut Washer 59497 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1D-7...
Page 62 59500 Description lb‑in. lb‑ft Link rod bolt – Locknut – Secure the battery cables to the throttle/shift cable with two cable ties to prevent contact with the steering components. 59502 Page 1D-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 63: Installing Jet Outboard
Installing Jet Outboard Mercury Marine Validated Engine Mounting Hardware IMPORTANT: Mercury Marine provides validated fasteners and installation instructions, including torque specifications, with all of our outboards so they can be properly secured to boat transoms. Improper installation of the outboard can cause performance and reliability issues that can lead to safety concerns.
Page 64: Selecting Accessories For Your Outboard
Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories.
Page 65: Fastening The Outboard
Apply marine sealer to shanks of bolts (purchase locally). Do not apply marine sealer to the threads of the bolts. Fasten the outboard with provided mounting hardware shown. Tighten mounting hardware securely. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1D-11...
Page 66: Steering Bracket, Steering Cable Installation
Always use required components and follow instructions and torque procedures. Page 1D-12 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 67 Install the loose end of the steering link onto the steering cable and secure with a washer and locknut. Tighten the locknut securely and then back the nut off 1/4 turn. Washer Locknut 59499 Tighten the link rod bolt to the specified torque. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1D-13...
Page 68: Electrical Harness, Battery Connection, Fuel Tanks
Remove the three access cover bolts. Remove the access cover and cable rubber grommet. 10113 Remove the cotter pin retainers and washers from the shift actuating lever, shift link, and throttle actuating lever. Remove the shift link from the shift actuating lever. Page 1D-14 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 69 10. Install the shift link to the shift actuating lever. Washer and cotter pin retainer securing shift link Shift actuating lever Harness retainer bracket bolt Shift link 10135 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1D-15...
Page 70: Battery Cable Connections
Move the remote control handle from neutral into forward and advance the handle to full speed position. NOTE: The throttle cable is the second cable to move when moving the control box out of neutral. Page 1D-16 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 71: Shift Cable Installation
Make a center mark ("c"), midway between marks ("a" and "b"). Align the cable end guide with this center mark when installing cable to the engine. 6098 Ensure the engine is in neutral. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1D-17...
Page 72 Cable barrel retainer bolt Cable grommet 15855 Description lb. in. lb. ft. Cable barrel retainer bolt Install the access cover and secure with three bolts. Tighten bolts to the specified torque. 15858 Page 1D-18 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 73: Control Cable Installation - Jet Outboard
Adjust the throttle cable barrel if the cam roller is touching the cam. Cam roller Throttle cam 15952 Install the cable grommet. Secure the throttle cable barrel with the cable barrel retainer. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1D-19...
Page 74: Shift Cable Installation
Place the remote control handle into full forward position. Adjust the shift cable adjustment barrel so that the roller is at the full end of travel (bottom) in the shift cam. Page 1D-20 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 75: Installing Propeller
IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), 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. 10087 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 1D-21...
Page 76 Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends. 28353 28351 Description lb‑in. lb‑ft Propeller nut – Page 1D-22 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 77 Flywheel Assembly............. 2A-8 Throttle Position Sensor (TPS)......... 2A-33 Stator................2A-8 TPS Test..............2A-34 Stator Testing............. 2A-9 Tiller Handle Stop Button and Lanyard Stop Switch Flywheel Removal and Installation......2A-11 Test............... 2A-35 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-1...
Page 78: Ignition Specifications
Data link harness between the engine ECM and the Computer Diagnostic System (CDS). 22175 Adapter Harness 84‑822560A7 Data link harness between the engine ECM and the Computer Diagnostic System (CDS). 13422 Page 2A-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 79: Theory Of Operation
(duration). The ECM uses all of the sensor to monitor the engines condition which are directly related to the warning system. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-3...
Page 80: Troubleshooting Without A Computer Diagnostic System (Cds)
The ECM is 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. The CDS has been developed specifically to help technicians diagnose and repair Mercury Marine 2 and 4 cycle engines. CDS G3 Diagnostic Tool Kit 8M0114141 Attach the 84‑899150T01 diagnostic cable to the ECM diagnostic port and attach the 84‑822560A7 adapter to the...
Page 81: Fault Information
Ignition key is OFF, lanyard stop switch active: displayed in the CDS as ON. Stop Switch Ignition key is ON, lanyard stop switch is open: displayed in the CDS as OFF. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-5...
Page 82: Warning System
NOTE: Should overheating occur and you are stranded, stop the engine and allow it to cool down. This will usually allow some additional low speed (idle) running time before the engine starts to overheat again. Page 2A-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 83: Low Oil Pressure
Excessive overspeed (above 6300 RPM) will result in cutout of the cylinders to prevent operation above this limit. Warning Light and Warning Horn Wire Diagrams Warning Light Wire Diagram ECM engine harness connector Warning light WHT/RED LT GRN 22604 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-7...
Page 84: Warning Horn Wire Diagram-Tiller Handle Models
There is also a heavy gauge wire wound on the bobbins to generate voltage required to maintain the battery. This voltage is rectified external of the ECM. Page 2A-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 85: Stator Testing
Test the three stator battery charge windings for continuity. DMT 2004 Digital Multimeter 91‑892647A01 NOTE: The stator is not polarity sensitive when checking ohm resistant values. Positive meter lead connection Negative meter lead connection 9979 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-9...
Page 86 Test each of the stator windings to engine ground. If continuity is found, replace the stator. Stator Battery Charge Windings Resistance to Ground Meter scale Auto range Reading (ohms) Open Ignition Charge Windings DVA Output Test ECM engine harness connector Stator WHT/RED WHT/BLK WHT/BLU 22580 Page 2A-10 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 87: Flywheel Removal And Installation
400 volt 46 volts 36 volts 218 volts Record Mode Flywheel Removal and Installation Flywheel Removal Remove the timing belt cover and recoil assembly. Refer to Section 8 ‑ Manual Starter. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-11...
Page 88 Install a three point flywheel puller onto the flywheel. Do not use a jaw type puller on the ring gear. Tighten the flywheel puller until the flywheel is loose from the crankshaft. Bolts (3) Flywheel puller 9782 Flywheel Puller/Lifting Ring 91‑83164M Remove the flywheel. Page 2A-12 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 89 Use a flywheel holder to secure the flywheel and tighten the flywheel nut to the specified torque. Flywheel holder Torque wrench 9829 Description lb. in. lb. ft. Flywheel nut 110.5 Flywheel Holding Tool 91‑52344 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-13...
Page 90: Stator Removal And Installation
Clamp Battery charging connector Voltage regulator/recitifier connector Stator ignition charge connector 9856 Remove the three bolts securing the stator assembly to the coil bracket. Remove the stator. Bolts (3) 10117 Page 2A-14 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 91: Crank Position Sensor (Cps)
Remove the flywheel. Refer to Flywheel Removal and Installation. Cut the cable tie securing the CPS wire connector and the stator harness connector to the engine harness. Disconnect the CPS connector from the engine harness connector. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-15...
Page 92 Connect the CPS harness connector to the engine harness connector. Secure the CPS wire harness to the engine harness with a cable tie. Bolt with a clamp securing CPS Cable tie 22300 Page 2A-16 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 93 Crank position sensor bolt (2) 35.5 Install the flywheel. Refer to Flywheel Removal and Installation. Install the recoil assembly and timing belt cover. Refer to Section 8 ‑ Manual Starter. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-17...
Page 94: Crank Position Sensor Testing
Connect one of the meter leads to the CPS connector and the other meter lead to engine ground. DMT 2004 Digital Multimeter 91‑892647A01 Replace the CPS if out of specification. Page 2A-18 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 95 Insert the meter leads into the crank position sensor wire harness connector. DMT 2004 Digital Multimeter 91‑892647A01 NOTE: The CPS is not polarity sensitive. 9970 Meter Test Leads Meter Scale Reading (Ω) Black Red/White Black Auto range 148 ‑ 222 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-19...
Page 96: Electronic Control Module (Ecm)
Connect the engine harness connector to the ECM. Install the fuse holder to the ECM. Engine harness plug ECM diagnostic access Fuse holder Bolt securing ECM (2) 9899 Description lb. in. lb. ft. Bolt securing ECM Page 2A-20 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 97: Ignition Coils
Secure the ignition coil to the cylinder head with the ignition coil mounting bolt. Tighten the ignition coil mounting bolt to the specified torque. Description lb. in. lb. ft. Ignition coil mounting bolt 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-21...
Page 98: Ignition Coil Testing
NOTE: It is not necessary to remove the ignition coils from the powerhead for testing. Disconnect the ignition coil from the engine harness connector. Page 2A-22 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 99 Engine ground (coil mounting bolt) Coil secondary winding (coil high tension lead) 9954 Meter Test Leads Meter Scale Reading (Ω) Black Coil high tension lead Engine ground Auto range 3.3 ‑ 4.9k 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-23...
Page 100: Engine Temperature Coolant Sensor (Etc)
ETC Installation Cover the threads of the ETC sensor with Loctite 567 PST Pipe Sealant. Thread the ETC sensor into the cylinder block. Tighten the ETC sensor to the specified torque. Page 2A-24 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 101: Etc Sensor Test
Place the engine temperature coolant sensor in a container filled with water. Place a thermometer in the water and slowly heat the water. Measure the resistance when the specified temperature is reached. If out of specification, replace the sensor. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-25...
Page 102: Oil Pressure Sensor
Bolt securing the VST (2) 11584 Slide the oil pressure switch protection boot off the oil pressure switch. 11589 Remove the screw securing the engine harness wire to the oil pressure switch. Page 2A-26 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 103 Oil pressure switch threads 92-809822 Sealant Dielectric Grease Oil pressure switch wire connection 92-823506 1 Description lb. in. lb. ft. Oil pressure switch Screw securing the oil pressure sensor wire 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-27...
Page 104: Oil Pressure Switch Test
Connect the red lead of an ohm meter to the terminal and the black lead to the oil pressure switch metal body. Using a controllable air pressure source, apply air pressure to the oil pressure switch. Check for continuity specification. Page 2A-28 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 105: Manifold Air Temperature (Mat) Sensor
Grommets in the intake manifold Bolts securing the electrical cover (2) 10493 Pull the MAT sensor out of the rubber grommet. Remove the engine harness connector from the MAT sensor. MAT sensor 11578 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-29...
Page 106 Install the electrical cover into the grommets in the intake manifold and secure with two bolts, and spacers. Tighten to the specified torque. Grommets in the intake manifold Bolts securing the electrical cover (2) 10493 Description lb. in. lb. ft. Bolts securing the electrical cover (2) Page 2A-30 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 107: Mat Sensor Test
The MAP sensor signal voltage is used by the ECM programed logic to determine the optimum fuel injection timing, ignition timing, and fuel injection duration. MAP Sensor Removal and Installation MAP Sensor Removal Disconnect the engine harness connector from the MAP sensor. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-31...
Page 108 Secure the MAP sensor to the MAP sensor mounting bracket with a bolt. Tighten the bolt to the specified torque. Connect the engine harness connector to the MAP sensor. Description lb. in. lb. ft. Bolt Page 2A-32 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 109: Map Sensor Test
The throttle position sensor (TPS) transmits throttle angle information to the ECM. The ECM uses this information to vary the injector pulse width and ignition timing accordingly. The TPS is non‑serviceable. Replace the throttle body with the TPS if the sensor is not within specifications. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-33...
Page 110: Tps Test
3.2 ‑ 3.8 k Idle 3.8 ‑ 4.6 k Auto 1.2 ‑ 1.6 k NOTE: The throttle position sensor operation can be measured the the CDS tool. CDS G3 Diagnostic Tool Kit 8M0114141 Page 2A-34 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 111: Tiller Handle Stop Button And Lanyard Stop Switch Test
Set the lanyard stop switch to the "OFF" position. The meter should show continuity. If no continuity is found, the lanyard stop switch is defective and must be replaced. Set the safety switch to the "RUN" position. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2A-35...
Page 112 Push on the stop button to activate the stop switch. The meter should show continuity. If no continuity is found, the stop button is defective and must be replaced. DMT 2004 Digital Multimeter 91‑892647A01 Page 2A-36 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 113 Starter Motor Disassembly........2B-40 Battery Charging System Description.......2B-15 Starter Motor Reassembly........2B-41 Troubleshooting Battery Charging System....2B-15 Starter Motor Installation...........2B-44 Voltage Regulator/Rectifier Description....2B-15 Voltage Regulator/Rectifier Removal and Installation ................2B-15 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-1...
Page 114: Charging And Starting Specifications
H z TEMP reads in high RFI environments. TEMP C O M 4516 Hose Clamp Tool Kit 91‑803146A2 Aids in the installation of high pressure (Oetiker ®) hose clamps. 5819 Page 2B-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 116: Electrical Bracket And Cover
Charging and Starting System Electrical Bracket and Cover 16662 Page 2B-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 117 Bushing Bolt (M6 x 20) Support bracket Wire connector retainer Bolt Warning Horn (tiller handle only) MAT sensor Grommet Hose Hose Bolt Washer Bushing Rubber mount Plate Washer Nut (M6) 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-5...
Page 118: Flywheel, Ecu, And Wiring Harness
Charging and Starting System Flywheel, ECU, and Wiring Harness 24 25 20518 Page 2B-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 119 Clamp Plug Coil bracket Bolt Trigger Screw Trigger Ignition coil Boot Bolt Clamp Plug ECU bracket Bolt Washer Washer Bolt Spacer Rubber mount Terminal plug ECU harness Cable tie Clamp 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-7...
Page 120: Starter Motor And Rectifier
Charging and Starting System Starter Motor and Rectifier 20 21 17115 Page 2B-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 121 Bolt Plate Bolt Washer Spacer Rubber mount MAP sensor Screw (M6 x 16) Clip Hose Water temperature sensor 194.7 O‑ring Fuse harness Fuse (20 ampere) Terminal plug Bolt Start switch 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-9...
Page 122: Starter Motor Components
Charging and Starting System Starter Motor Components 16663 Page 2B-10 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 123 Charging and Starting System Starter Motor Components Torque Ref. No. Qty. Description lb. in. lb. ft. Starter motor Pinion Washer Brush holder Screw Bushing O‑ring Bushing Washer Lockwasher 88.5 Bolt Lockwasher Washer 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-11...
Page 124: Battery
IMPORTANT: Only use copper battery cables. Do not use aluminum cables for any outboard marine installations. • If longer battery cables are required, the wire gauge size must increase. See chart following for correct wire gauge size. Wire gauge size Battery cable length 2758 Page 2B-12 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 125: Replacement Parts
Replacement Parts WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all components.
Page 126: Recommended Battery
Grease terminal bolts with 2‑4‑C with PTFE and store the battery in a cool‑dry place. Remove the battery from storage every 30–45 days, check the water level, and put on charge for 5 or 6 amps. Do not fast charge. Page 2B-14 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 127: Battery Charging System
Cut the cable tie securing the voltage regulator/rectifier stator connector to the engine harness. Disconnect the voltage regulator/rectifier harness connector. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-15...
Page 128 Secure the voltage regulator/rectifier to the intake manifold. Do not tighten the bolt at this time. Install a bolt in the upper mounting hole of the voltage regulator/rectifier mounting hole and secure to the intake manifold. Page 2B-16 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 129 (2) 20822 Connect the voltage regulator/rectifier stator connector to the stator connector. Secure the voltage regulator/rectifier stator connector to the engine harness with a cable tie. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-17...
Page 130: Wire Color Code Abbreviations
Wire Color Abbreviations Black Blue Brown GRY or GRA Gray Green ORN or ORG Orange Pink PPL or PUR Purple White Yellow LT or LIT Light DK or DRK Dark Page 2B-18 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 131: Regulator/Rectifier Diode Test
The voltage regulator/rectifier can be checked while installed on the engine. The following tests are only standard values and are difficult to obtain accurately. Due to variables in temperature and the meter manufacture, test values may vary. DMT 2004 Digital Multimeter 91‑892647A01 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-19...
Page 132: Engine Wire Harness (Remote Control)
Remove the two bolts and spacers securing the wire cover. Pull the wire cover from the grommets in the intake manifold. Grommets in the intake manifold Bolts and spacers securing the wire cover (2 each) 10493 Page 2B-20 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 133 MAP sensor harness connector 10456 13. Disconnect the water temperature sensor harness connector. 14. Disconnect the trim extension harness connector from the cowl mounted trim switch connector. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-21...
Page 134 Cable tie securing the air vent assembly vent hose High pressure fuel pump harness connector Clamp Trigger harness connector Oil pressure sender harness connector 10468 23. Remove the engine harness from the clamp. Page 2B-22 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 135 33. Remove the wire connector retainer. 34. Disconnect the trim harness connector. 35. Disconnect the trim up solenoid wire connector (blue). 36. Disconnect the trim down solenoid wire connector (pink). 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-23...
Page 136: Engine Wire Harness Installation (Remote Control)
NOTE: Refer to the wire harness connection diagram located on the back side of the electrical cover for all wire harness connections. 21199 Orientate the engine harness so the 14 pin connector is pointing towards the rear starboard side of the engine. Page 2B-24 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 137 12. Connect the engine harness Throttle Position Sensor (TPS) connector to the TPS. Snap the TPS connector into the wire connector retainer. 13. Connect the engine harness green wire connector to the green starter relay exciter wire connector. Install the green connector into the wire connector retainer. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-25...
Page 138 Tighten the bolt to the specified torque. 18. Secure the negative battery cable and the engine harness ground wire to the starter with a bolt and washer. Tighten the bolt to the specified torque. Page 2B-26 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 139 26. Install the fuel cooler mounting bracket to the cylinder block and secure with a boLT Do not tighten the bolt at this time. 27. Install the air vent assembly to the top of the fuel cooler mounting bracket. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-27...
Page 140 37. Install the fuse holder onto the mounting bracket. 38. Connect the voltage regulator sensing lead connector to the engine harness. Secure the voltage regulator sensing lead connector to the engine harness with two cable ties. Page 2B-28 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 141 43. Install the recoil assembly and the timing belt cover. Refer to Section 8A ‑ Manual Starter. Grommets in the intake manifold Bolts securing the wire cover (2) 10493 Description lb. in. lb. ft. Bolts (2) 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-29...
Page 142: Engine Wire Harness (Tiller Handle)
21186 Cut the three cable ties securing the ignition charge connector, trigger, and the alternator connector to the engine wire harness. Disconnect the ignition charge connector. Disconnect the trigger connector. Page 2B-30 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 143 11. Disconnect the water temperature sensor harness connector. Water temperature sensor harness connector Ignition coil harness connectors (3) 21189 12. Remove the bolt securing the air vent assembly to the cylinder block. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-31...
Page 144 20. Remove the bolt securing the engine harness ground wire to the bracket. TPS harness connector MAT sensor harness connector Bolt securing the engine harness ground wire 21196 21. Disconnect the low oil pressure warning lamp bullet connectors. Page 2B-32 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 145: Engine Wire Harness Installation (Tiller Handle)
(black, black/yellow, brown) Warning horn Warning horn connector IAC connector 21197 Secure the engine wire harness ground wire to the bracket with a bolt. Tighten the bolt to the specified torque. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-33...
Page 146 12. Install the fuel cooler mounting bracket to the cylinder block and secure with a bolt. Do not tighten the bolt at this time. 13. Install the air vent assembly to the top of the fuel cooler mounting bracket and secure with a bolt. Page 2B-34 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 147 17. Connect the engine harness MAP sensor connector to the MAP sensor. 18. Connect the engine harness trigger connector to the trigger. 19. Connect the engine harness ignition charge connector to the stator. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-35...
Page 148 Bolts and spacers securing the electrical cover (2) 10493 Description lb. in. lb. ft. Bolts (2) 24. Install the recoil assembly and timing belt cover. Refer to Section 8A ‑ Manual Starter. Page 2B-36 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 149: Starter Motor
Connect a 12 volt power supply between the black wire "3", and the green wire "4". The solenoid should click and the meter should read 0 ohms (full continuity). If the meter does not read 0 ohms (full continuity), replace the solenoid. 21356 DMT 2004 Digital Multimeter 91‑892647A01 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-37...
Page 150: Starting System Troubleshooting Chart
Starter Neutral start switch Ignition key switch Remote Control Models Battery Fuse ‑ 20 ampere Starter relay Starter Neutral start switch Ignition key switch 23300 DMT 2004 Digital Multimeter 91‑892647A01 Page 2B-38 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 151: Starter Motor Removal
Remove the support bracket and the IAC filter. Remove the engine oil filter. Remove the high pressure fuel hose clamp at the VST and remove the fuel hose. Remove the air vent assembly hose from the VST. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-39...
Page 152: Starter Motor Disassembly
Bolts securing the starter brace to the cylinder block (2) 10497 Starter Motor Disassembly Push the pinion stopper down and remove the circlip. Remove the pinion stopper, bendix spring, and bendix. Circlip Pinion stopper Bendix 10500 Page 2B-40 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 153: Starter Motor Reassembly
Nut securing power stud to insulator End cap insulator Screw securing brush card Brushes 10503 Starter Motor Reassembly Install the power stud insulator onto the power stud. Insert the power stud through the end cap. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-41...
Page 154 Install the top thrust washer and shims onto the armature. IMPORTANT: The thrust washer must be installed first onto the armature. The shims must be between the end cap and the thrust washer. Page 2B-42 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 155 13. Install the field frame to the end cap. Ensure the locating key of the field frame and the end cap are aligned. 10537 14. Lubricate the armature shaft with SAE Engine Oil 30W and install the top end cap. Ensure the locating keys are in alignment. 10539 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-43...
Page 156: Starter Motor Installation
Tighten the bolts to the specified torque. Install one of the starter brace bolts into the cylinder block. Do not tighten the bolt. Page 2B-44 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 157 High pressure fuel hose clamp (16.8 mm) Bolts and washer securing VST Air vent assembly hose Oil filter 10495 Hose Clamp Tool Kit 91‑803146A2 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2B-45...
Page 158 11. Install the wire harness. Refer to Engine Wire Harness for the installation of the engine wire harness. 12. Check the engine oil level. Add engine oil as required. 13. Start the engine and inspect for fuel leaks. Page 2B-46 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 159 Timing Belt Installation ..........2C-4 Maximum Timing Adjustment (All Models)......2C-2 Throttle Linkage Adjustment (Tiller Handle)...... 2C-6 Timing Belt Removal and Installation ....... 2C-3 Throttle Linkage Adjustment (Remote Control)....2C-8 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2C-1...
Page 160: Ignition Specifications
Maximum Timing Adjustment (All Models) Maximum timing is not adjustable. Maximum timing is controlled by the PCM/ECM. Maximum timing can be monitored with the Computer Diagnostic System (CDS). CDS G3 Diagnostic Tool Kit 8M0114141 Page 2C-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 161: Timing Belt Removal And Installation
Crankshaft flywheel key Cylinder block timing mark Cylinder head timing mark Cam gear timing mark 9932 Crankshaft Holding Tool 91‑898101360 Remove the timing belt tensioner bolt. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2C-3...
Page 162: Timing Belt Installation
9944 Ensure the crankshaft drive gear timing mark and the cylinder block timing mark are in proper alignment. Flywheel key Crankshaft drive gear timing mark Cylinder block timing mark 9945 Page 2C-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 163 10. Secure the lifting bracket to the engine block with two bolts. Tighten the bolts to the specified torque. Bolts securing stator/CPS mounting plate Bolts securing lifting bracket 9931 Description lb. in. lb. ft. Bolts securing stator/CPS mounting plate (3) Bolts securing lifting bracket (2) 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2C-5...
Page 164: Throttle Linkage Adjustment (Tiller Handle)
21249 Description lb. in. lb. ft. Shift detent spring bolt Remove the upper throttle rod from the throttle body. Do not remove the upper throttle rod from the throttle arm. Page 2C-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 165 12. Check to ensure the throttle cam does not move when the throttle arm is against the WOT stop. Throttle cam Upper throttle rod 21274 13. Ensure the lower throttle rod is fully threaded onto the joint. Do not tighten the jam nut. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2C-7...
Page 166: Throttle Linkage Adjustment (Remote Control)
Throttle Linkage Adjustment (Remote Control) Push the throttle arm to the WOT position. The throttle arm must contact the throttle arm stop to ensure the throttle linkage is adjusted correctly. Page 2C-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 167 Check to ensure the throttle arm is contacting the throttle arm stop. Throttle arm at the WOT position No movement on throttle cam when pushed Throttle arm contacting the throttle arm stop 22610 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 2C-9...
Page 169 Actuators................3A-5 Fuel Cooler..............3A-3 Function of Actuators..........3A-5 Throttle Body.............. 3A-3 Engine Control Module..........3A-5 Sensors................3A-3 Idle Air Control (IAC)...........3A-6 Function of Sensors............3A-3 Fuel Injector..............3A-7 Crank Position Sensor (CPS)........3A-4 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3A-1...
Page 170: Theory Of Operation
Excess fuel flows through the pressure regulator back to the vapor separator tank. 21110 Page 3A-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 171: Fuel Pressure Regulator
ECM. The sensors, in conjunction with the ECM, manage the fuel system, the ignition system, and the warning system, based on the information received from these condition and location sensors. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3A-3...
Page 172: Crank Position Sensor (Cps)
Should the sensor fail or become disconnected, the warning horn will sound intermittently, the warning lamp will be intermittent, and the engine RPM will be reduced to 2800 or less. The engine must be stopped to cancel the warning. 21105 Page 3A-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 173: Manifold Air Temperature (Mat) Sensor
Directly controls the ground circuit of fuel injectors, ignition coils, high‑pressure fuel pump, and idle air control. • Indirectly controls the positive circuit of fuel injectors, ignition coils, and idle air control. • Controls alarm horn and warning functions. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3A-5...
Page 174: Idle Air Control (Iac)
Controls idle speed according to the varying engine loads, and running conditions. • Functions as an electronic dashpot by providing additional bypass air as the throttle quickly closes during a rapid deceleration, preventing engine stalling. 21101 Page 3A-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 175: Fuel Injector
An injector filter is located on the fuel inlet side of the injector. The filter is not replaceable, but can be cleaned of debris. 21100 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3A-7...
Page 177 Guardian Warning System Control Matrix......3B-5 Troubleshooting with the Computer Diagnostic System Anti‑Siphon Valves.............3B-6 (CDS)................3B-3 Testing Fuel Lift Pump Vacuum.........3B-6 Accessing ECM Information with the CDS......3B-4 Fuel Pressure Test.............3B-7 Fault Information............3B-5 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3B-1...
Page 178 Tests the fuel pump pressure; can be used to relieve fuel pressure. 2807 Dual Fuel/Air Pressure Gauge Kit 91‑881834A 1 Tests fuel and air pressure; the dual gauges allow the viewing of both pressures simultaneously. 5822 Page 3B-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 179: Troubleshooting Without A Computer Diagnostic System (Cds)
The ECM is 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. The CDS has been developed specifically to help technicians diagnose and repair Mercury Marine 2 and 4 cycle engines. CDS G3 Diagnostic Tool Kit...
Page 180: Accessing Ecm Information With The Cds
The CDS will not clear (erase) faults hours at the time of this service manual printing. The System Information screen will display an alpha‑numeric code identifying a specific calibration in the ECM. Page 3B-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 181: Fault Information
The warning horn will emit either a continuous beep or intermittent short beeps and the engine speed will be limited. This will alert the operator and help identify the following listed situations. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3B-5...
Page 182: Anti-Siphon Valves
Install a fuel vacuum gauge (obtain locally) on the t‑fitting. Clamp all fuel line connections securely to prevent vacuum leaks. Start engine. Observe clear fuel line for air bubbles. 1. Stop engine to cancel warning notification. Page 3B-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 183: Fuel Pressure Test
NOTE: The ambient barometric air pressure will have a direct affect on the fuel pressure reading. 9999 Fuel Pressure Specification at 850 RPM 294 kPa (42.6 psi) Fuel Pressure Gauge Kit 91‑881833A03 Dual Fuel/Air Pressure Gauge Kit 91‑881834A 1 Digital Pressure Meter 91‑892651A01 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3B-7...
Page 185 VST Disassembly............. 3C-22 Idle Air Control (IAC)............3C-48 VST Reassembly............3C-24 IAC Removal............3C-48 VST Installation............3C-29 IAC Installation............3C-50 Fuel Cooler..............3C-31 Wire Color Code Abbreviations........ 3C-52 Fuel Cooler Removal..........3C-31 IAC Test..............3C-53 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-1...
Page 186: Fuel System Specifications
Tests fuel and air pressure; the dual gauges allow the viewing of both pressures simultaneously. 5822 Digital Pressure Meter 91‑892651A01 Connects to the fuel system/manifold and can be used in conjunction with Computer Diagnostic System (CDS). 5786 Page 3C-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 187 Measures RPM on spark ignition (SI) engines, ohms, amperes, AC and DC voltages; records maximums and minimums simultaneously, and accurately H z TEMP reads in high RFI environments. TEMP C O M 4516 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-3...
Page 188: Fuel Pump Components
Service Procedures Fuel Pump Components 18679 Page 3C-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 189 Fuel cooler gasket Fuel filter Hose Fuel cooler Bolt Hose Connector Clamp (16.8) Hose Clip Rubber mount Bracket High pressure fuel filter Hose Clamp Fitting Hose Sleeve Hose Hose Collar Cable tie 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-5...
Page 190: Fuel Rail And Vapor Separator Components
Service Procedures Fuel Rail and Vapor Separator Components 18685 Page 3C-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 191 Screw Nipple O‑ring Clip Clip Hose Vent fitting Cable tie Clamp Orifice Air vent assembly Clip Hose Hose Clamp (16.8) Hose Vapor separator Bolt Clamp Washer Grommet Spacer Grommet Sleeve 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-7...
Page 192: Fuel Cooler And Vapor Separator Components
Service Procedures Fuel Cooler and Vapor Separator Components 18695 Page 3C-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 193 Grommet O‑ring Drain screw O‑ring Screw Insulator Grommet Fuel pump Filter Inlet needle and seat Clip Float Screw O‑ring Drain screw Drain screw O‑ring Hose Fuel cooler Screw O‑ring O‑ring 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-9...
Page 194: Intake Manifold Components
Service Procedures Intake Manifold Components 19527 Page 3C-10 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 195 Bolt Washer O‑ring Insulator Throttle body assembly Gasket Bolt Grommet Air horn Bolt Spring Washer Bushing Bolt Bracket Bolt Grommet Intake silencer Cover Gasket Filter Self tapping screw Plug Band 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-11...
Page 196: Fuel Lift Pump
Push the cowl latch pivot rod to the port side to remove from the cowl latch lever. Do not lose the washers located between the cowl latch pivot rod and the lower cowl. NOTE: Some models do not have washers between the cowl latch pivot rod and the lower cowl. Washers (4) 11611 Page 3C-12 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 197: Fuel Lift Pump Disassembly And Reassembly
Fuel Lift Pump Disassembly and Reassembly Fuel Lift Pump Disassembly Remove the O‑ring seal from the fuel pump. Remove the four T20H Torx screws from the fuel pump. O‑ring T20H Torx screw 10032 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-13...
Page 198 Install the plunger spring and plunger onto the fuel pump diaphragm housing. Compress the diaphragm and plunger. Insert the diaphragm pin into the plunger. Fuel pump plunger Diaphragm pin Fuel pump diaphragm housing Diaphragm 10034 Page 3C-14 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 199 10. Install the fuel pump screws. Tighten the fuel pump screws to the specified torque. 11. Install the O‑ring. O‑ring T20H Torx screw 10032 Description lb. in. lb. ft. Fuel pump screws (T20H Torx) 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-15...
Page 200: Fuel Lift Pump Installation
Install the cowl latch seal onto the lower cowl. Ensure the cowl latch seal fulcrum is in proper position on the lower cowl during the installation. Cowl latch seal fulcrum Lower cowl Fuel pump 11614 Page 3C-16 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 201 10. Install the cowl latch pivot rod detent spring and bolts. Tighten the bolts to the specified torque. Bolt securing cowl latch pivot rod (2) Cowl latch detent spring Cowl latch lever 11610 Description lb. in. lb. ft. Bolt securing cowl latch pivot rod (2) 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-17...
Page 202: High Pressure Fuel Filter
Oil filter Bolt securing high pressure fuel filter bracket High pressure fuel filter Water separating fuel filter 16852 Pull the high pressure fuel filter up and out of the cowl area. Page 3C-18 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 203: High Pressure Fuel Filter Installation
Install the fuel filter bracket to the fuel filter grommet. Fuel filter grommet Fuel filter bracket 21176 Secure the fuel filter bracket to the cylinder block with a bolt. Tighten the bolt to the specified torque. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-19...
Page 204: Vapor Separator Tank (Vst)
Install a fuel pressure gauge onto the fuel rail Schrader valve and release any pressurized fuel into an appropriate container. Schrader valve 10216 Fuel Pressure Gauge Kit 91‑881833A03 Dual Fuel/Air Pressure Gauge Kit 91‑881834A 1 Page 3C-20 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 205 Remove the vent hose from the air vent assembly. Disconnect the high pressure fuel pump wire harness connector. 10. Remove the two bolts securing the VST to the cylinder block. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-21...
Page 206: Vst Disassembly
15. Lift the VST up to remove the VST drain hose from the bottom cowl. 20394 VST Disassembly Remove the washers, grommets, and spacers from the VST assembly. Remove the VST vent hose. Page 3C-22 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 207 Pull the high pressure fuel pump from the VST cover. 10. Remove the insulator cover protecting the wires on the high pressure fuel pump. 11. Remove the wires on the high pressure fuel pump. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-23...
Page 208: Vst Reassembly
15. Push on the high pressure fuel pump wire harness assembly retaining tabs to remove the wire harness assembly from the VST cover. Retaining tabs 10260 VST Reassembly Fuel Pump Reassembly Install the fuel pump base to the high pressure fuel pump. Install the grommet to the fuel pump base. Page 3C-24 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 209 Ensure wire harness connector retaining tabs hold the connector into the VST cover. Retaining tabs 10260 Fuel Inlet Needle And Float Installation Install the fuel inlet needle clip. Needle clip Fuel inlet needle 10344 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-25...
Page 210 High Pressure Fuel Pump Assembly Installation Push the high pressure fuel pump grommet onto the VST cover. Ensure the high pressure fuel pump grommet is seated and level on the VST cover. 10353 Page 3C-26 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 211 Black wire Fuel pump wire insulator 10356 Push fuel pump into the high pressure fuel pump grommet. 10357 VST Cover Installation Install a new seal onto the VST tank. 10358 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-27...
Page 212 Install a new seal onto the fuel pressure regulator. 10362 Install the VST cover to the VST tank. Secure VST cover to the VST tank with five screws. Tighten the screws to the specified torque. Page 3C-28 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 213: Vst Installation
Spacer (2) Grommet (2) Grommet (2) Washer (2) VST vent hose Assembled grommet VST drain hose 16735 VST Installation Insert the VST drain hose through the bottom cowl opening. 10324 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-29...
Page 214 Install a clamp onto a VST bolt. Install a washer onto the bolt. Install the bolt with the clamp and washer onto the upper VST mounting grommet. Install the remaining VST bolt and washer into the rear VST mounting grommet. Tighten the VST bolts to the specified torque. Page 3C-30 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 215: Fuel Cooler
Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any spilled fuel immediately. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-31...
Page 216 Remove the fuel cooler water delivery hose. Remove the clamp securing the fuel hose coming from the VST. Remove the fuel hose. Fuel hose coming from the VST Fuel cooler water delivery hose 10380 Page 3C-32 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 217: Fuel Cooler Disassembly And Reassembly
Remove the four screws (two on each side) securing the fuel cooler end caps to the fuel cooler manifold. 10551 Fuel Cooler Reassembly Use compressed air to remove debris from the fuel cooler manifold. Install new O‑rings onto the fuel cooler end caps. 9833 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-33...
Page 218: Fuel Cooler Installation
Install a 16.8 mm diameter hose clamp onto the fuel hose coming from the VST. Secure the fuel hose coming from the VST to the fuel cooler. Crimp the hose clamp using a hose clamp tool. Fuel hose coming from VST Fuel cooler water delivery hose 10380 Page 3C-34 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 219: Throttle Body
Remove the two bolts securing the air horn to the bracket. Disconnect the crankcase breather hose and remove the air horn from the throttle body. Air horn Crankcase breather hose Bolts securing the air horn (2) 11517 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-35...
Page 220: Throttle Body Disassembly And Reassembly
If the TPS has failed, or the throttle butterfly adjustment screw was tampered with, a throttle body assembly must be ordered. Remove the bolt securing the throttle cam to the throttle body. Page 3C-36 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 221 Install the return spring onto the throttle body. 11538 Bolt Washer Throttle cam Bushing Washer Return spring Throttle body Apply Loctite 242 Threadlocker to the bolt threads retaining the throttle cam to the throttle body. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-37...
Page 222: Throttle Body Installation
Install four bolts to secure the bracket to the cylinder block. Do not tighten the bolts at this time. Install a bolt with a clamp, in the upper corner of the bracket, next to the starter mount. Page 3C-38 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 223 Bolts securing the throttle body Connect the throttle actuating link to the throttle cam. Throttle actuating link Throttle cam 11519 Install the crankcase breather hose onto the air horn. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-39...
Page 224: Fuel Rail
Always protect eyes and skin from pressurized fuel and vapors. Disconnect the battery cable from the battery. Page 3C-40 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 225 Pull the fuel rail assembly off the intake manifold. Fuel injector harness connector (3) Fuel rail bolt (3) Clamp 11635 Remove the spring clamp securing the fuel hose to the fuel rail inlet tube. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-41...
Page 226: Fuel Rail Disassembly
Install new O‑rings onto the fuel inlet tube. O‑rings (2) 11643 Lubricate the fuel inlet tube O‑rings with 10W‑30 4‑Stroke Marine Engine Oil. Install the fuel inlet tube onto the fuel rail. Page 3C-42 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 227 Fuel rail Schrader valve 92-8M0078625 Engine Oil Description lb. in. lb. ft. Screw Inspect the fuel injector filter. NOTE: The fuel injector filter is a nonserviceable component but can be cleared of debris. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-43...
Page 228: Fuel Rail Installation
Lubricate the fuel injector seals with a light oil. Install the fuel rail assembly to the intake manifold. Secure the fuel rail to the intake manifold with three bolts. Tighten the bolts to the specified torque. Page 3C-44 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 229: Intake Manifold
Remove the IAC. Refer to Section 3C ‑ Idle Air Control (IAC). Remove the fuel rail. Refer to Section 3C ‑ Fuel Rail. Remove the six bolts securing the intake manifold to the cylinder block and cylinder head. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-45...
Page 230: Intake Manifold Installation
NOTE: The larger end of the grommet must face the rear of the ECM mounting bracket. Install the spacers inside the three grommets. Install the washer onto the three grommets. Washer (3) Spacer (3) Grommet (3) ECM mounting bracket 11170 Page 3C-46 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 231 Nuts and bolts securing the intake manifold ( 6 bolts, three nuts,) 11. Install the fuel rail. Refer to Section 3C ‑ Fuel Rail. 12. Install the IAC. Refer to Section 3C ‑ Idle Air Control (IAC). 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-47...
Page 232: Idle Air Control (Iac)
Remove the bolt securing the support bracket to the electrical bracket. Nut securing the two ground wires Bolt securing the two solenoid ground wires, and the starter relay ground wire Bolt securing the support bracket 20897 Page 3C-48 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 233 Upper IAC bracket bolts and washers (2) Lower IAC bracket bolt and washer (1) Remove the nut and washer securing the IAC valve to the IAC bracket. 10599 Remove the IAC filter from the electrical bracket. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-49...
Page 234: Iac Installation
Description lb. in. lb. ft. IAC nut 88.5 Secure the IAC bracket to the electrical bracket with three bolts, washers, and rubber grommets. Tighten the bolts to the specified torque. Page 3C-50 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 235 Install the two solenoid ground wires and the starter relay ground wire onto the support bracket bolt. Secure the support bracket with the bolt and ground wires. Tighten the bolt to the specified torque. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-51...
Page 236: Wire Color Code Abbreviations
Wire Color Abbreviations Black Blue Brown GRY or GRA Gray Green ORN or ORG Orange Pink PPL or PUR Purple White Yellow LT or LIT Light DK or DRK Dark Page 3C-52 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 237: Iac Test
84‑825003A 1 Apply 69 kPa (10 PSI) vacuum to the top port of the IAC. Ensure the IAC holds the vacuum pressure. Apply 12 volts to the terminals of the IAC. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3C-53...
Page 238 Right terminal pin Left terminal pin Auto 24.0 ‑ 30.0 Connect the DMT 2004 Digital Multimeter tool to the terminal pins of the IAC. 23017 DMT 2004 Digital Multimeter 91‑892647A01 Page 3C-54 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 239 Oxides of Nitrogen – NOx...........3D-2 Manufacturer's Certificate Label........3D-3 Controlling Emissions..........3D-2 Service Replacement Certification Label......3D-3 Stoichiometric (14.7:1) Air/Fuel Ratio......3D-2 Removal..............3D-3 Emissions Information............3D-2 Date Code Identification..........3D-4 Manufacturer's Responsibility........3D-2 Installation..............3D-4 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 3D-1...
Page 240 United States Environmental Protection Agency (EPA). A certification decal/emissions control information label, showing emission levels and engine specifications directly related to emissions, must be placed on each engine at the time of manufacture. Page 3D-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 241 EPA Emission Regulations All new 1998 and newer outboards manufactured by Mercury Marine for operation in the USA, 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.
Page 242 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.
Page 243 Cylinder Block Assembly..........4A-20 Cylinder Block Disassembly..........4A-11 Piston Installation............4A-20 Crankcase Disassembly........... 4A-11 Crankshaft Installation..........4A-21 Flywheel................4A-14 Thermostat and Anode Installation......4A-23 Crankshaft Drive Gear............. 4A-14 Powerhead Reassembly...........4A-24 Timing Belt............... 4A-14 Powerhead Installation.............4A-27 Anode................4A-14 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-1...
Page 244: Cylinder Block/Crankcase Specifications
Oil ring end gap 0.2–0.7 mm (0.008–0.028 in.) Lubricants, Sealants, Adhesives Tube Ref No. Description Where Used Part No. Oil pressure switch threads Loctite 567 PST Pipe 92-809822 Sealant Water temperature sender threads Page 4A-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 245 Flange screw O-ring Cylinder head cover seal Three Bond 1217F Cylinder block crankcase mating surface 92-858005K02 Special Tools Piston Ring Compressor FT2997 Compresses the piston rings to ease piston installation 8745 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-3...
Page 246: Cylinder Block Components
Cylinder Block/Crankcase Cylinder Block Components 17 18 12907 Page 4A-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 247 Dowel pin Lifting eye Bolt 88.5 Thermostat Gasket Bolt Bolt (M6 x 16) Anode Gasket Anode plug Bolt (M6 x 20) Oil filter 159.3 Gasket Plunger Clamp Hose Strainer Dipstick 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-5...
Page 248: Crankshaft, Piston, And Connecting Rod Components
Cylinder Block/Crankcase Crankshaft, Piston, And Connecting Rod Components 12908 Page 4A-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 249 Crankshaft Bearing Upper oil seal Lower oil seal Connecting rod First torque Bolt (M7 x 1.0) Final torque Piston Piston ring set Piston pin Piston pin retainer 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-7...
Page 250: Powerhead Removal
Bolts securing the horizontal shift shaft bracket (2) Horizontal shift shaft 11178 13. Move the horizontal shift shaft to the starboard side to disengage the upper shift shaft from the horizontal shift shaft. Page 4A-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 251 15. Remove the crankcase ventilation hose. 20942 16. Remove the hose on top of the air vent assembly. 20943 17. Remove six bolts (three each side) securing the powerhead to the driveshaft housing. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-9...
Page 252: Powerhead Components Removal
Fuel cooler water delivery hose from the cylinder block Fuel filter Fuel cooler Fuel pump Intake manifold Timing belt Remove the cylinder head. Refer to Section 4B ‑ Cylinder Head. Page 4A-10 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 253: Cylinder Block Disassembly
Remove the thermostat cover and the thermostat. Remove the anode cover bolts. Remove the anode cover. Thermostat cover bolts Anode cover bolts. 11735 Crankcase Disassembly Remove the starter lock cable bracket. Starter lock cable bracket 11593 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-11...
Page 254 11627 Remove the connecting rod cap bolts and the connecting rod caps. IMPORTANT: Do not intermix the connecting rod caps with the connecting rods. Remove the crankshaft. Page 4A-12 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 255 Reinstall the connecting rod caps. Tighten the connecting rod cap bolts finger tight. 11605 10. Push the piston and connecting rod assembly out of the cylinder block. 11606 11. Remove the main bearings from the cylinder block and crankcase cover. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-13...
Page 256: Flywheel
Carefully move the gauge up and down the cylinder bore to determine taper. Turn the gauge to different points around the cylinder wall to determine the out of round condition. Page 4A-14 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 257: Measuring Piston
The minimum piston to cylinder wall clearance is defined by the formula: Minimum cylinder bore measurement ‑ Maximum piston diameter measurement = Piston to cylinder clearance. Piston To Cylinder Wall Clearance Minimum clearance 0.020–0.055 mm (0.00079–0.00217 in.) Maximum clearance (service limit) 0.150 mm (0.00591 in.) 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-15...
Page 258 Piston Ring End Gap 0.15–0.30 mm (0.0059–0.0118 in.) Top (service limit) 0.50 mm (0.0197 in.) Middle 0.35–0.50 mm (0.0138–0.0197 in.) Middle (service limit) 0.70 mm (0.0276 in.) 0.20–0.70 mm (0.0079–0.0276 in.) Page 4A-16 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 259: Crankcase Main Bearings
Install the main bearing halves into the cylinder block. NOTE: Align each bearing projection with the notch in the cylinder block. Place a piece of plastigauge onto each of the crankshaft bearing surfaces. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-17...
Page 260 10. If the oil clearance is out of specification limit, measure the inside diameter of the cylinder block and crankcase cover main bearing journals. SELECTING NEW MAIN BEARINGS Locate the main bearing code on the cylinder block. Page 4A-18 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 261: Connecting Rod Oil Clearance
IMPORTANT: Install connecting rods in their original locations (#1, #2 and #3). Make sure that the "UP" mark on the connecting rod cap faces towards the flywheel end of the crankshaft. Place a piece of plastigauge on the crankpin journals. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-19...
Page 262: Cylinder Block Assembly
Using the piston ring compressor tool, install the piston/connecting rod assembly into the cylinder block. Push down on the piston compressor tool to ensure that the tool is firmly seated against the block. Page 4A-20 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 263: Crankshaft Installation
Assemble the connecting rods to the crankshaft and install the connecting rod caps. Secure the connecting rod caps with two bolts. Tighten the connecting rod cap bolts in two steps to the specified torque. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-21...
Page 264 13. Install starter lock cable bracket. Secure the starter lock cable bracket with a bolt. Tighten the bolt to the specified torque. 11593 Description lb. in. lb. ft. Starter lock cable bracket bolt 14. Install the drive gear key into the crankshaft. Page 4A-22 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 265: Thermostat And Anode Installation
Cam drive gear nut Cam drive gear Belt tensioner 11588 Thermostat and Anode Installation Install the thermostat, thermostat cover gasket, and thermostat cover. Secure the thermostat cover with two bolts. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-23...
Page 266: Powerhead Reassembly
Thermostat cover bolts (2) Anode flange screw Powerhead Reassembly Install the cylinder head.Refer to Section 4B ‑ Cylinder Head Installation. Coat the oil pressure switch threads with Loctite 567 PST Pipe Sealant. Page 4A-24 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 267 Description Where Used Part No. Loctite 567 PST Pipe Water temperature sender threads 92-809822 Sealant Description lb. in. lb. ft. Water temperature sender 16.2 Install a key into the camshaft. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-25...
Page 268 13. Install the powerhead assembly onto the driveshaft housing. Refer to Powerhead Installation, following. 14. Install the fuel components. Refer to Section 3C ‑ Fuel System. 15. Install the electrical components. Refer to Section 2A ‑ Electrical. Page 4A-26 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 269: Powerhead Installation
Install the high pressure fuel hose to the fuel rail. Secure the high pressure fuel hose with a spring clamp. Install the fuel cooling hose onto the cylinder block. Connect the fuel hose from the fuel filter outlet, to the fuel pump inlet. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-27...
Page 270 11. Secure the powerhead to the adapter plate with six bolts (three each side). Tighten the powerhead mounting bolts to the specified torque. Powerhead mounting bolts (3 each side) 20944 Description lb. in. lb. ft. Powerhead mounting bolts (3 each side) Page 4A-28 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 271 15. Engage the upper shift shaft with the horizontal shift shaft. 16. Insert the horizontal shift shaft into the shift shaft bracket. Interlock cable Upper shift shaft Horizontal shift shaft Shift shaft bracket 20965 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4A-29...
Page 272 18. Install the shift link to the horizontal shift shaft. Secure the the shift link to the horizontal shift shaft with a washer and cotter pin. 19. Connect the throttle actuating link to the throttle cam. Throttle actuating link Shift link 11453 Page 4A-30 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 273 Cylinder Head Reassembly..........4B-16 Cylinder Head Removal........... 4B-10 Valve Installation............4B-16 Cylinder Head Disassembly........4B-11 Cam and Rocker Installation........4B-17 Cleaning and Inspection..........4B-13 Cylinder Head Installation..........4B-19 Valves............... 4B-13 Valve Adjustments............4B-21 Valve Springs............4B-14 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4B-1...
Page 274: Cylinder Head Specifications
0.006–0.035 mm (0.0003–0.0014 in.) Cylinder head upper camshaft bearing inside diameter 18.01–18.025 mm (0.709–0.710 in.) Oil pump camshaft bearing inside diameter 18.01–18.025 mm (0.709–0.710 in.) Valve stem seal color Intake Black Exhaust Green Page 4B-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 275 Camshaft, cylinder head and camshaft bearing surface 10W-30 4-Stroke Marine Intake rocker shaft 92-8M0078625 Engine Oil Exhaust rocker shaft Cylinder head bolt threads Special Tools Valve Spring Compressor 91‑809494A1 Removes and installs valve springs. 3454 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4B-3...
Page 276: Cylinder Head Components
Cylinder Head Cylinder Head Components 12904 Page 4B-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 277 Oil fill cap O‑ring First Torque Bolt (M6 x 53) Final Torque Decal Clamp Gasket Spark plug Plug Gasket First Torque Bolt (M6 x 53) Final Torque 88.5 Washer Plate Bolt Hose 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4B-5...
Page 278: Camshaft And Timing Belt Tensioner Components
Cylinder Head Camshaft and Timing Belt Tensioner Components 21009 Page 4B-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 279 Bolt (M6 x 45) Washer Camshaft seal Camshaft gear Bolt (M6 x 20) Washer Timing belt Belt tensioner Tensioner cover Bolt (M10 x 40) Washer Spring Hook Lockwasher Plate Drive pulley 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4B-7...
Page 280: Intake And Exhaust Valve Components
Cylinder Head Intake and Exhaust Valve Components 16659 Page 4B-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 281 Intake valve stem seal (black) Exhaust valve stem seal (green) Seat Spring Retainer Keeper Rocker arm Adjusting screw Rocker arm shaft (intake) Rocker arm shaft (exhaust) Bolt Spring Washer Spacer Spring 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4B-9...
Page 282: Cylinder Head Removal
Remove the two fuel pump retaining bolts. Remove the fuel pump. 10. Remove the eight cylinder head cover bolts. 11. Remove cylinder head cover. Cylinder head cover bolts (8) Fuel pump retaining bolts (2) 11485 Page 4B-10 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 283: Cylinder Head Disassembly
Remove the oil galley cover bolt. Remove the oil galley cover. NOTE: Note the position of the spacer at the bottom of the rocker shaft. Spacer Rocker shaft retaining bolts (2) Oil galley cover bolt 11496 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4B-11...
Page 284 Compress the valve springs using a valve spring compressor. 11502 Remove the keepers, upper seats, springs, lower seats, and valves. Valve Spring Compressor 91‑809494A1 NOTE: The valve seals are not reusable. Page 4B-12 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 285: Cleaning And Inspection
5.46–5.48 mm (0.215–0.216 in.) Exhaust 5.44–5.46 mm (0.214–0.215 in.) Measure the margin thickness of the valve. Replace the valve if out of specification. 20972 Valve Margin thickness 5.0 mm (0.197 in.) minimum 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4B-13...
Page 286: Valve Springs
Apply a light downward pressure on the head. Move the head in the pattern shown. Rotate the head several times during the resurfacing procedure to avoid removing material from one side. Thoroughly clean all sanding grit from the cylinder head. 3007 Page 4B-14 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 287: Valve Guides
45° Rough surface of valve seat 20954 Use the 30° cutting tool to adjust the contact width of the top edge of the valve seat. Previous contact width 30° 20976 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4B-15...
Page 288: Cylinder Head Reassembly
NOTE: Valve seals are color coded to ensure they are installed onto the proper valve guide. The black valve seal is for the intake. The green valve seal is for the exhaust. Page 4B-16 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 289: Cam And Rocker Installation
Install the upper camshaft seal. Lubricate the upper camshaft seal lip with 2‑4‑C with PTFE. Camshaft seal 11488 Tube Ref No. Description Where Used Part No. 2-4-C with PTFE Camshaft seal lip 92-802859A 1 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4B-17...
Page 290 Lubricate the intake rocker shaft with 10W‑30 4‑Stroke Marine Engine Oil. Install the intake rocker shaft, washers, springs, and rocker arms. IMPORTANT: Install the washers with the rounded edge toward the rocker arm. Washer Rocker arm 11492 Page 4B-18 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 291: Cylinder Head Installation
Install the camshaft gear key onto the camshaft. Install the camshaft gear onto the camshaft. Install the washer and bolt to retain the camshaft gear. Tighten the bolt to the specified torque. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4B-19...
Page 292 10. Install the cylinder head cover onto the cylinder head. Secure the cylinder head cover with eight bolts. Tighten the cylinder head cover bolts in two steps to the specified torque. Page 4B-20 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 293: Valve Adjustments
Turn the flywheel 240° and align the third mark (III) on the camshaft gear with the timing mark on the cylinder block. Adjust the intake and exhaust valve clearance for cylinder #3. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4B-21...
Page 294 Description lb. in. lb. ft. Locknut Install the spark plugs. Install the cylinder head cover. Install the flywheel cover and timing belt cover. Refer to Section 8A ‑ Recoil Starter. Page 4B-22 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 295 Section 4C - Oil Pump Table of Contents Oil System Specifications ..........4C-2 Oil Pump Inspection............4C-6 Oil Flow................4C-4 Oil Pump Reassembly............4C-6 Oil Pump Removal.............4C-5 Oil Pump Installation............4C-8 Oil Pump Disassembly............4C-5 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4C-1...
Page 296: Oil System Specifications
Oil pump driveshaft, oil pump cover seal 92-802859A 1 Oil pump base seal 10W-30 4-Stroke Marine Inlet and outlet of the oil pump, cylinder head oil pump bore, 92-8M0078625 Engine Oil camshaft Page 4C-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 299: Oil Pump Removal
Remove the oil pump cover screws. Oil pump cover screws (2) 11568 Remove the cover and discard the oil pump cover seal. Push the oil pump shaft out of the oil pump body. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4C-5...
Page 300: Oil Pump Inspection
Oil Pump Reassembly Lubricate the rotor cavity of the oil pump with 2‑4‑C with PTFE. Lubricate the outer rotor with 2‑4‑C with PTFE. Install the outer rotor into the oil pump body. Page 4C-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 301 Install the oil pump cover and secure with two screws. Tighten the screws to the specified torque. Oil pump cover screw (2) 11568 Description lb. in. lb. ft. Oil pump cover screw (2) 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4C-7...
Page 302: Oil Pump Installation
Secure the oil pump to the cylinder head with three bolts. Tighten the bolts to the specified torque. Oil pump bolt (3) 11499 Description lb. in. lb. ft. Oil pump bolt (3) Page 4C-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 303 Cooling System Powerhead Section 4D - Cooling System Table of Contents Cooling System Specifications.......... 4D-2 Thermostat.................4D-3 Cooling System Description..........4D-2 Thermostat Measurement Test........4D-3 Water Flow Diagram............4D-3 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4D-1...
Page 304 To allow complete passage filling and to prevent steam pockets, all cooling passages are interconnected. Small passages are incorporated into the cooling system, to allow the cooling system to drain while the outboard is in a normal operating position. Page 4D-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 305 IMPORTANT: Do not allow the thermometer to contact the heating surface of the container. An inaccurate temperature reading may result. Slowly heat the water while observing the thermostat and thermometer. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 4D-3...
Page 306 Cooling System Measure the thermostat opening when the specified water temperature is achieved. 3120 Minimum thermostat valve lift Page 4D-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 307 Swivel Bracket/Clamp Bracket Installation....5A-53 Upper Motor Mount Replacement........5A-21 Gearcase/Reverse Hook Operation.........5A-54 Removal ‑ Power Trim Models......... 5A-21 Operation..............5A-54 Removal ‑ All Models..........5A-21 Adjustments.............. 5A-55 Installation ‑ All Models..........5A-24 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-1...
Page 308 Tilt stop bracket pivot guide 92-802859A 1 Swivel bracket and steering shaft Special Tools Torch Lamp 91‑63209 Heats surfaces to aid in the removal and installation of interference fit engine components. 8776 Page 5A-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 310: Driveshaft Housing Components
Clamp/Swivel Bracket, Driveshaft Housing Driveshaft Housing Components 16666 Page 5A-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 311 Tapping screw Drive tight Washer Skirt seal Skirt seal Grommet Idle exhaust cover Bolt Idle exhaust cover gasket Plate Gasket Grommet Plate Gasket Rubber seal Adapter plate Oil seal Gasket 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-5...
Page 312: Swivel Bracket Components
Clamp/Swivel Bracket, Driveshaft Housing Swivel Bracket Components 16672 Page 5A-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 313 Screw (M6 x 16) (handle) Collar (handle) Steering shaft assembly Washer Lock plate 20.3 179.7 Mount retainer Bolt Rubber mount (upper) Upper lock retainer Rubber damper (upper) Screw (upper) 20.3 179.7 Upper damper 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-7...
Page 314 Clamp/Swivel Bracket, Driveshaft Housing Tube Ref No. Description Where Used Part No. 2-4-C with PTFE Grease fittings and co-pilot handle bolt 92-802859A 1 Page 5A-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 315 Clamp/Swivel Bracket, Driveshaft Housing Swivel Bracket Components 16672 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-9...
Page 316: Clamp Bracket Components - Power Trim And Gas Assist
Clamp/Swivel Bracket, Driveshaft Housing Clamp Bracket Components ‑ Power Trim and Gas Assist 16673 Page 5A-10 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 317 Anode Bolt Tilt stop Grip Spring Collar Upper cylinder spring Bolt Washer Power trim/tilt assembly Bushing Bushing Cable tie (8 in.) Shock absorber (Gas) Lever Grip Button Bolt Washer Collar 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-11...
Page 318: Clamp Bracket Components - Manual Tilt
Clamp/Swivel Bracket, Driveshaft Housing Clamp Bracket Components ‑ Manual Tilt 22848 Page 5A-12 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 319 Bolt Washer Cotter pin Link bushing Link Tilt stop bracket Bolt Plate Bracket Stop Friction spring Reverse lock lever Reverse lock lever grip Button Bolt 97.3 Wave washer Washer Spring 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-13...
Page 320 Clamp/Swivel Bracket, Driveshaft Housing Torque Ref. No. Qty. Description lb. In. lb. ft. Page 5A-14 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 321 Clamp/Swivel Bracket, Driveshaft Housing Clamp Bracket Components - Manual Tilt 22848 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-15...
Page 322: Driveshaft Housing Cover
Port exhaust cover bolts (8) 9395 Port Cover Installation Clean the gasket surfaces on the driveshaft housing and port exhaust cover before installing a new gasket. Install a new gasket. Page 5A-16 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 323: Rear Cover Removal
Tighten the bolts in sequence to the specified torque. 9991 Description lb. in. lb. ft. Port exhaust cover bolt (8) Rear Cover Removal Remove the six bolts securing the exhaust cover. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-17...
Page 324 Install the rear exhaust cover and secure with six bolts. Rear exhaust cover gasket surface Rear exhaust cover Cover bolts (6) 10010 Tighten the bolts in sequence to specified torque. 10011 Page 5A-18 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 325: Lower Motor Mount Replacement
Install a bolt through the swivel yoke. Install a washer on the bolt and push the bolt through the lower motor mount. Install a new rubber washer over the lower motor mount. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-19...
Page 326 Attach the two ground cables to the starboard lower motor mount bolt. Tighten the cover bolts to specified torque. Cover screws Lower motor mount cover Ground cable (2) 10035 Description lb. in. lb. ft. Lower motor mount cover bolt Page 5A-20 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 327: Upper Motor Mount Replacement
On tiller handle models, remove the throttle only assembly. Refer to Section 7A. Remove the upper shift shaft from the horizontal shift lever shaft. Refer to Section 7A. Remove the flywheel cover and flywheel. Refer to Section 2A. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-21...
Page 328 Reverse lock hook Upper shift shaft Push the upper shift shaft up through the powerhead assembly until it clears the swivel bracket. Do not pull the upper shift shaft through the grommet. Page 5A-22 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 329 12. While holding the upper shift shaft, remove the swivel bracket/clamp bracket/steering arm assembly from the driveshaft housing and adapter plate. Driveshaft housing Steering arm Clamp bracket assembly Swivel bracket 18821 13. Remove the two bolts and the mount retainer securing each upper motor mount. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-23...
Page 330: Installation - All Models
Inspect each upper motor mount cavity for corrosion or debris. Ensure that the bore is clean before installing new motor mounts. Install an upper damper in each upper motor mount cavity. 18828 Adapter plate Upper motor mount cavity Upper damper Page 5A-24 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 331 Description lb. in. lb. ft. Upper motor mount retaining bolts Push the upper shift shaft up through the powerhead assembly until it clears the swivel bracket. Upper shift shaft 20966 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-25...
Page 332 10. Install the lower motor mounts. Refer to Lower Motor Mount Replacement, preceding. 11. On manual tilt models: Assemble the reverse lock link to the upper shift shaft. Install the reverse lock link into the bushing and reverse lock hook. Page 5A-26 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 333: Installation - Power Trim And Gas Assist Models
16. Install the lower cowl cover. Refer to Section 7B. 17. Install the driveshaft housing cover. Refer to Driveshaft Housing Cover, preceding. Installation ‑ Power Trim and Gas Assist Models Route the power trim harness through the clamp. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-27...
Page 334: Clamp Bracket/Swivel Bracket - Power Trim And Gas Assist Models
Clamp Bracket/Swivel Bracket ‑ Power Trim and Gas Assist Models Clamp Brackets ‑ Removal and Installation Port Clamp Bracket Removal Remove the two bolts securing the anode to the clamp brackets. Page 5A-28 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 335 Harness clamps (2) Tilt pin and cotter pin Lower pivot pin, bushing, washer, and snap ring 19142 Remove the port clamp bracket. Inspect the bushings and washers. Replace if required. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-29...
Page 336 Lower pivot pin, bushing, washer, and snap ring 19142 Description lb. in. lb. ft. Tilt tube nut 17.7 Power trim harness clamp bolt 11. Route the power trim harness through the bottom cowl. Page 5A-30 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 337 Remove the transom bolts from the starboard clamp bracket. Bolt and ground cable Anode Bolt Port clamp bracket Lower pivot pin Starboard clamp bracket Bushing 19141 Loosen the tilt tube nut from the port side. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-31...
Page 338 Lower pivot pin, bushing, washer, and snap ring Tilt pin Tilt lock lever 19220 Move the starboard clamp bracket away from the swivel bracket. Remove the ground cable from the swivel bracket. Page 5A-32 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 339 Starboard clamp bracket Ground cable and bolt 19225 Description lb. in. lb. ft. Ground cable bolt Install a washer on the tilt tube. Install the clamp bracket assembly on the tilt tube. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-33...
Page 340: Swivel Bracket/Clamp Bracket Removal
13. Reinstall the transom bolts through the starboard clamp bracket. Swivel Bracket/Clamp Bracket Removal Power Trim Models Remove the electrical plate cover and disconnect the power trim wires from the solenoids. Pull the wire harness through the bottom cowl. Page 5A-34 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 341 NOTE: The upper shift shaft may be held in this position by clamping a Vice Grip® pliers to it. 11. While holding the upper shift shaft, remove the swivel/clamp brackets from the driveshaft housing and adapter plate. Refer to Upper Motor Mount Replacement, preceding. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-35...
Page 342: Swivel Bracket - Disassembly And Reassembly
Use a dead blow hammer to remove the bottom yoke from the steering shaft assembly. Torch lamp Dead blow hammer Bottom yoke 19379 Torch Lamp 91‑63209 Wait until the steering shaft is cool. Remove the washer, O‑ring, and bushing from the steering shaft. Page 5A-36 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 343 Tighten the port clamp bracket clamp screw and install the transom bolts through the port clamp bracket. Push the lower pivot pin through both clamp brackets. Install the snap ring and washer from the lower pivot pin. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-37...
Page 344 Install the thrust washer and bushing on the steering arm. Install the steering shaft assembly in the swivel bracket. Steering shaft assembly Thrust washer Bushing Swivel bracket 19014 Push the steering shaft assembly completely into the steering bracket. Page 5A-38 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 345 Bottom yoke Torch lamp Dead blow hammer 19869 Torch Lamp 91‑63209 10. Install the snap ring to the steering shaft assembly. 11. Install the ground cable to the bottom yoke. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-39...
Page 346: Swivel Bracket/Clamp Bracket Installation
Install the locknut on the lower motor mount bolt. Install the two bolts securing the lower motor mount cover to the driveshaft housing. 10. Remove the chain hoist from the powerhead lift eye. 19355 Page 5A-40 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 347: Clamp Bracket/Swivel Bracket - Manual Tilt Models
NOTE: If only one clamp bracket is being removed, the outboard may remain on the transom. Loosen the clamp screws. Remove the outboard from the transom. Remove the tilt stop pin and clamp bracket stud. Remove the starboard side tilt tube locknut. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-41...
Page 348: Reverse Lock Hook
Bolt and washer Tilt bushing Port clamp bracket Tilt tube 20852 Reverse Lock Hook Removal Pry the bushing open and remove the reverse lock link from the bushing and reverse lock hook. Page 5A-42 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 349 Install the spring on the swivel housing with the spring loops placed over the bosses on the swivel bracket. Slide the reverse lock hook under the hooks on the spring. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-43...
Page 350 Tighten the shoulder bolt to specified torque. Reverse lock hook Shoulder bolt (2) Spring 20830 Description lb. in. lb. ft. Reverse lock hook shoulder bolt 97.3 Attach the reverse lock link to the upper shift shaft. Page 5A-44 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 351: Reverse Lock Lever
Attach the spring to the reverse lock lever and the spring hook pin. Tilt Stop Bracket Removal Remove the two bolts securing the tilt stop plate to the swivel bracket. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-45...
Page 352 Description Where Used Part No. 2-4-C with PTFE Tilt stop bracket pivot guide 92-802859A 1 Position the tilt stop bracket so the pin is between the reverse lock lever stops. Page 5A-46 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 353: Clamp Bracket Installation
Ensure that the tilt stop bracket pin is positioned between the stops on the reverse lock lever. Position the tilt end of stop bracket in the clamp bracket tilt slot. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-47...
Page 354 Install the starboard clamp bracket on the tilt tube. Position the end of tilt stop bracket in the clamp bracket tilt slot. 20859 Install the tilt stop pin and clamp bracket stud. Page 5A-48 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 355: Swivel Bracket/Clamp Bracket Removal
Remove the upper shift shaft from the shift lever. Refer to Section 7A ‑ Throttle Only Removal. Removal Remove the flywheel cover and flywheel. Refer to Section 2A ‑ Flywheel Removal. Attach a chain hoist hook to the powerhead lift eye. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-49...
Page 356: Swivel Bracket - Disassembly And Reassembly
Remove the ground cable bolt from the bottom yoke. Remove the snap ring from the steering shaft assembly. Rubber damper Bottom yoke Ground cable bolt Steering shaft assembly Snap ring 20900 Page 5A-50 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 357 11. Remove the clamp brackets from the swivel bracket. Refer to Clamp Bracket Removal, preceding. Reassembly Assemble the clamp brackets to the swivel bracket. Refer to Clamp Bracket Installation, preceding. Install a thrust washer and bushing on the steering arm. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-51...
Page 358 Hold the steering shaft assembly. Use a dead blow hammer to install the bottom yoke on the steering shaft assembly. Steering shaft assembly Bottom yoke Torch lamp Dead blow hammer 20904 Torch Lamp 91‑63209 Page 5A-52 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 359: Swivel Bracket/Clamp Bracket Installation
Description lb. in. lb. ft. Lower motor mount locknut Install the two bolts securing the lower motor mount covers to the driveshaft housing. Refer to Lower Motor Mount Installation, preceding. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-53...
Page 360: Gearcase/Reverse Hook Operation
Rotate the shift handle grip to the neutral position. Ensure that the following conditions are met: • Gearcase is in neutral (propeller rotates in both directions). • Resistance should not be felt when the propeller shaft is rotated in either direction. Page 5A-54 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 361: Adjustments
Reverse hook is engaged. Adjustments Lower shift shaft and coupler adjustments: Refer to Section 6A ‑ Gear Housing Installation. Throttle cable adjustments: Refer to Section 7B ‑ Throttle Cable/Linkage Adjustments. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5A-55...
Page 363 Power Trim Pump Reassembly........ 5B-28 Troubleshooting the Power Trim System......5B-10 Power Trim Cylinder............5B-31 Preliminary Troubleshooting Steps......5B-10 Power Trim Cylinder Disassembly......5B-31 Hydraulic System Troubleshooting......5B-10 Power Trim Cylinder Reassembly......5B-34 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-1...
Page 364: Power Trim Specifications
Measures RPM on spark ignition (SI) engines, ohms, amperes, AC and DC voltages; records maximums and minimums simultaneously, and accurately H z TEMP reads in high RFI environments. TEMP C O M 4516 Page 5B-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 366: Power Trim/Tilt Components
Power Trim Power Trim/Tilt Components 16674 Page 5B-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 367 Snap ring Valve seat Ball Spring seat Spring O‑ring Pump Coupling Bolt O‑ring Motor assembly O‑ring Reservoir tank Cap assembly O‑ring Screw PTT switch O‑ring Switch bracket Screw (M6 x 16) 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-5...
Page 368: Power Trim General Information
Increase steering torque or pull to the left at a normal installation height (with the normal right‑hand rotation propeller.) • In excess, can cause boat porpoising (bouncing) or propeller ventilation. • Cause engine overheating if any cooling water intake holes are above the waterline. Page 5B-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 369: Checking Power Trim Fluid
Remove the fill cap and check the fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim and Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.
Page 370: Wire Color Code Abbreviations
Wire Color Code Abbreviations Wire Color Abbreviations Black Blue Brown Gray Green ORN or ORG Orange Pink PPL or PUR Purple White Yellow LT or LIT Light DK or DRK Dark Page 5B-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 371: Theory Of Operation
Trim down pressure operated check valve Return valve Trim cylinder Impact relief valve Shock piston Memory piston Up circuit thermal relief valve Down circuit thermal relief valve Manual release valve 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-9...
Page 372: Operation
1, 2, 6, 7, 8, 9, 10, 12 Starts to trim up from full down position when the down trim button is depressed. 3, 4 Trim position does not hold in reverse. 2, 3, 4, 5, 12 Page 5B-10 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 373: Electrical System Troubleshooting
Internal motor problem (brushes, shorted armature). Check for open connection. Replace motor. Trim switch failure. Replace switch. Verify relays are functioning correctly. Check voltage at Relay not operating. trim bullets. DMT 2004 Digital Multimeter 91‑892647A01 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-11...
Page 374 Blue relay terminal Ground Voltage ‑ DC Battery voltage (12V) Replace the relay that does not switch the lead to positive. Reconnect the heavy gauge pump wires to the trim control relay. Page 5B-12 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 375 LT BLU 18511 Down power trim relay Up power trim relay Starter relay Fuse To rectifier Starter motor Remote control Battery Fourteen pin engine harness connector Power trim cowl switch 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-13...
Page 376 Power Trim Power trim unit Red wire (pin A) Light blue wire (pin H) Pink wire (pin J) Brown/white wire (pin K) Page 5B-14 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 377 Power Trim Power Trim Electrical Circuit - Tiller Handle 18512 Down power trim relay Up power trim relay Starter relay Fuse To rectifier Starter motor 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-15...
Page 378 • Tiller handle models: Go to Step 4. point 8. Depress the up trim button. No battery voltage measured: • Go to Step 3. Page 5B-16 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 379 8 and black lead to battery ground. trim switch. • Check black ground wires for connection or poor ground at point Depress up trim button. • Pump motor is faulty. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-17...
Page 380: Power Trim Removal
Remove the trim cylinder rod pin retaining screw and washer. Push the trim cylinder rod pin through the bore from the port side. Tilt cylinder rod pin retaining screw and washer Tilt cylinder rod pin 10514 Page 5B-18 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 381: Power Trim Installation
Extend the power trim cylinder rod until it aligns with the hole in the tilt bracket. Engage the tilt lock. Push the trim cylinder rod pin through the bore from the port side. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-19...
Page 382: Manual Release Valve Removal And Repair
NOTE: Additional fluid may be present in the reservoir. Place a drain pan under the power trim unit when removing the manual release valve. Fill plug Manual release valve Snap ring Power trim assembly 10550 Remove and discard the two O‑rings and backup ring from the manual release valve. Page 5B-20 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 383: Power Trim Motor
Remove the two 4 mm internal hex screws securing the motor assembly to the power trim pump and cylinder assembly. Separate the reservoir tank from the power trim pump and cylinder assembly. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-21...
Page 384: Power Trim Motor Disassembly, Inspection And Repair
Remove the armature from the motor bracket. Test for Short Test the armature on a Growler. Follow Growler manufacturer's test instructions. Indication of a short requires replacement of the armature. Page 5B-22 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 385 If specific readings are not obtained, check for: • Defective armature • Dirty or worn brushes • Dirty or worn commutator If defective components are found, repair or replace the component and retest. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-23...
Page 386: Power Trim Motor Reassembly
Hold the brushes in the slots while installing the armature in the motor bracket assembly. Install an O‑ring on the motor bracket assembly. Armature Motor bracket assembly Brush O‑ring 17159 Page 5B-24 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 387: Power Trim Motor Installation
Ensure that the pump/motor coupling is installed in the pump. Power trim pump Pump assembly mounting screws (4 mm internal hex) Pump/motor coupling 10961 Align the pump shaft tang with the slot in the pump/motor coupler. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-25...
Page 388 Power trim reservoir tank attaching screws (4 mm internal hex) Tube Ref No. Description Where Used Part No. Power Trim and Steering Power trim system reservoir 92-858074K01 Fluid Page 5B-26 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 389: Power Trim Pump
NOTE: Additional fluid may be present in the reservoir. Place a drain pan under the power trim unit when removing the reservoir. Reservoir tank Fill plug Cable tie Reservoir mounting screws (4 mm internal hex) 10954 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-27...
Page 390: Power Trim Pump Reassembly
Valve seat Ball Spring guide Spring 10965 Power Trim Pump Reassembly Install two new lubricated O‑rings into the power trim housing. Install a new lubricated O‑ring onto the check valve seat. Page 5B-28 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 391 Align the pump shaft tang with the slot in the pump/motor coupler. Attach the motor assembly to the power trim pump and cylinder assembly. NOTE: Position the trim motor assembly with the wire harness next to the trim cylinder. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-29...
Page 392 Tube Ref No. Description Where Used Part No. Power Trim and Steering Power trim system 92-858074K01 Fluid 14. Install the power trim assembly to the outboard. Refer to Power Trim Installation. Page 5B-30 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 393: Power Trim Cylinder
Use a hex wrench to remove the trim cylinder from the power trim assembly base by turning the cylinder counterclockwise. Disassembly after Removal IMPORTANT: Place the trim cylinder rod in a soft jaw vice. Scratching of the trim cylinder rod will result in external cylinder leakage. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-31...
Page 394 Remove the rod eye and jam nut. 18286 Outer cylinder tube Trim cylinder rod Jam nut Rod eye Remove paint, burrs, and sharp edges from the end of the trim rod. Page 5B-32 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 395 Memory piston 18275 Remove the trim piston rod assembly from the inner cylinder tube. 10. Remove the O‑ring from the piston. 18274 Inner cylinder tube Trim piston O‑ring Trim piston 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-33...
Page 396: Power Trim Cylinder Reassembly
Steering Fluid or Automatic Transmission Fluid (ATF) (Dexron Type III) prior to installation. Tube Ref No. Description Where Used Part No. Power Trim and Steering Power trim cylinder O-rings 92-858074K01 Fluid Page 5B-34 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 397 IMPORTANT: The trim piston assembly and the memory piston must be installed into the end of the inner cylinder tube with the inside diameter chamfer. Inner cylinder tube Chamfer on inside diameter 18288 Install a new lubricated O‑ring on the trim piston. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-35...
Page 398 IMPORTANT: Place the trim cylinder rod in a soft jawed vice. Scratching of the trim cylinder rod will result in external cylinder leakage. Place the trim cylinder rod in a soft jaw vice to install the rod eye and jam nut. Page 5B-36 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 399 Trim cylinder 15. Fill the power trim reservoir with fluid. Tube Ref No. Description Where Used Part No. Power Trim and Steering Power trim system reservoir 92-858074K01 Fluid 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5B-37...
Page 400 Power Trim 16. Install the power trim assembly to the outboard. Refer to Power Trim Installation, preceding. Page 5B-38 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 401 Section 5C - Gas Assist Manual Trim/Tilt Table of Contents Gas Assist Manual Trim/Tilt Components......5C-2 Gas Assist Assembly Bushing Replacement....5C-4 Gas Assist Manual Trim/Tilt System........5C-2 Installation..............5C-5 Removal..............5C-2 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5C-1...
Page 402: Gas Assist Manual Trim/Tilt Components
NOTE: The gas assist trim cylinder is not serviceable. If the cylinder is damaged, the unit must be replaced. IMPORTANT: Clamp the engine securely to the transom before tilting to prevent it from rolling off the transom when turning the engine. Page 5C-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 403 Remove the snap ring and steel washer from the lower pivot pin. Remove the lower pivot pin, collar, and gas assist trim cylinder. Gas assist trim cylinder Collar Steel washer Snap ring Lower pivot pin 18061 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5C-3...
Page 404: Gas Assist Assembly Bushing Replacement
Do not remove the cylinder end cap, internal hex plugs, or the plug from the gas assist trim cylinder. 18065 Rod eye bushing (2) Upper pivot bushing Cylinder end cap Internal hex plug (2) Plug Page 5C-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 405: Installation
Push the lower pivot pin through the starboard clamp bracket. Gas assist trim cylinder Port clamp bracket Collar Starboard clamp bracket Lower pivot pin 18068 Install a washer and snap ring. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 5C-5...
Page 406 Secure the upper pivot pin with a washer and retaining bolt. Tighten the bolt to specified torque. Washer Retaining bolt Upper pivot pin Tilt lock lever 18058 Description lb. in. lb. ft. Upper pivot pin retaining bolt Page 5C-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 407 Gearcase Lubricant Capacity........6A-44 Forward Gear and Reverse Gear Inspection....6A-24 Gearcase Lubricant Recommendation..... 6A-44 Driveshaft Pinion Bearing Inspection......6A-26 Checking Lubricant Level and Refilling Gearcase..6A-44 Upper Driveshaft Bearing Inspection......6A-26 Propeller Installation..........6A-45 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-1...
Page 408: Gearcase Specifications
Torch Lamp 91‑63209 Heats surfaces to aid in the removal and installation of interference fit engine components. 8776 Bearing Puller Assembly 91‑ 83165T Removes bearings, races and bearing carriers 3610 Page 6A-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 409 Removes the pinion nut; aids in the installation of the driveshaft bearing. 17189 Bearing Mandrel Kit 91‑83166M Aids in the removal and installation of bearings and bearing races. 3421 Pinion Height Tool 91‑895218 Aids in determining the pinion gear height. 17369 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-3...
Page 410 Aids in determining the forward gear backlash; use with a dial indicator. 12512 Dial Indicator 91‑58222A1 Measures gear backlash and pinion gear location. 29495 Dial Indicator Adapter 91‑83155 Attaches the dial indicator to the gearcase when checking backlash. 2999 Page 6A-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 412: Gear Housing (Driveshaft)
Gear Housing Gear Housing (Driveshaft) 16668 Page 6A-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 413 Gasket Impeller Pump liner housing Water pump housing Lower seal Bolt Upper grommet Water tube Rubber hose (long shaft) Bolt (long shaft) Washer Stud (short shaft) Nut (short shaft) Bolt 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-7...
Page 414: Gear Housing (Propeller Shaft)
Gear Housing Gear Housing (Propeller Shaft) 16667 Page 6A-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 415 Ball Holder Spring Clutch Spring Propeller shaft Washer Reverse gear (23 teeth) Bearing carrier O‑ring Ball bearing Needle bearing Oil seal Bolt Thrust hub Propeller Washer Prop nut Cotter pin 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-9...
Page 416: General Service Recommendations
Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate. Page 6A-10 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 417: Gear Housing Removal
Disable the ignition system by removing the keys from the ignition (if equipped) and engaging the lanyard stop switch to prevent the engine from starting. Remove the cotter pin from the propeller nut. Cotter pin Propeller nut 16913 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-11...
Page 418 17114 Design 1 model shift shaft coupler Upper shift shaft Coupler Upper shift shaft pin Lower shift shaft pin Page 6A-12 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 419: Gear Housing Disassembly
IMPORTANT: It is recommended that during complete disassembly of gear housing, all O‑rings and oil seals be replaced regardless of their appearance. Bearing Carrier Disassembly Remove the two bolts securing the bearing carrier. Bolts 16915 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-13...
Page 420 Remove the bearing carrier and propeller shaft assembly from the gearcase. Bearing carrier Propeller shaft 16918 NOTE: The cam follower and ball bearing are free to slide out of the propeller shaft. Cam follower Ball bearing Bearing carrier assembly 16919 Page 6A-14 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 421 Lamp to warm the bearing carrier where the reverse gear assembly is seated. Use a Bearing Puller Assembly to remove the reverse gear from the reverse gear bearing. Torch Lamp Reverse gear Bearing Puller Assembly 16923 Torch Lamp 91‑63209 Bearing Puller Assembly 91‑ 83165T 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-15...
Page 422 Use a screwdriver to remove the oil seal from the bearing carrier. Bearing carrier assembly Oil seal Screwdriver 16925 Use a suitable mandrel to press the needle bearing out of the bearing carrier. Bearing carrier Needle bearing (hidden) Mandrel 16928 Page 6A-16 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 423: Propeller Shaft Disassembly
Inspect the needle bearing surface of the propeller shaft for pitting and wear. Replace the shaft and bearing carrier if wear or pitting is present. Replace the propeller shaft if any of the following exist: 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-17...
Page 424: Water Pump, Driveshaft And Shift Shaft Disassembly
Water Pump, Driveshaft and Shift Shaft Disassembly Remove four screws from the water pump cover. Screws and washers Water pump cover 21035 Remove the water pump cover from the driveshaft. Water pump cover 21036 Page 6A-18 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 425 IMPORTANT: The circular groove formed by the impeller sealing bead should be disregarded when inspecting the liner and face plate. The depth of the groove will not affect the water pump output. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-19...
Page 426 10. Replace the liner and/or face plate if the grooves (other than sealing grooves) are more than 0.762 mm (0.030 in.) deep. 11. Remove the base gasket. Base gasket 21040 Page 6A-20 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 427 If the surface is damaged, replace the water pump base. Water pump base Seal 16971 14. Remove the screw and washer securing the shift shaft assembly. Shift shaft assembly Screw Washer 21043 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-21...
Page 428 16. To replace the shift cam, use a suitable punch to drive out the spring pin securing the shift cam to the shift shaft. Discard the spring pin. Punch Spring pin 6613 Page 6A-22 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 429 Outside O‑ring 16988 Tube Ref No. Description Where Used Part No. 2-4-C with PTFE Shift shaft bushing O-ring 92-802859A 1 22. Install the shift shaft bushing onto the shift shaft. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-23...
Page 430: Driveshaft Removal
Inspect the forward gear and reverse gear teeth for breakage, rust, chipping, and excessive wear. NOTE: Do not remove the forward gear race from the gearcase unless replacement is necessary. Page 6A-24 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 431 NOTE: Replace the forward gear bearing race located in the gearcase if the forward gear tapered bearing is replaced. Universal Puller Plate Tapered bearing Mandrel Forward gear 17008 Universal Puller Plate 91‑37241 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-25...
Page 432: Driveshaft Pinion Bearing Inspection
IMPORTANT: Do not remove the upper driveshaft tapered bearing from the driveshaft unless replacement is necessary. The removal process may damage the bearing. Inspect the upper driveshaft tapered bearing for rust, roughness, or excessive wear. Page 6A-26 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 433: Driveshaft Inspection
91‑853996 12 Universal Puller Plate 91‑37241 Driveshaft Inspection Inspect the splines at both ends of the driveshaft for a worn or twisted condition. Replace the driveshaft if either condition exists. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-27...
Page 434: Gear Housing Reassembly
Where Used Part No. Premium Gear Lubricant Inside diameter and outside diameter of pinion bearing 92-858058K01 Bearing Installation Tool 91‑895195001 Forward Gear Bearing Installation Place forward gear shim onto forward gear. Page 6A-28 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 435: Bearing Carrier Reassembly
Install the seal with the seal face up. Use a suitable mandrel from the Bearing Mandrel Kit to press the seal into the carrier until seated. Mandrel Seal (install face up) 17035 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-29...
Page 436 Use a suitable mandrel from the Bearing Mandrel Kit to press the reverse gear/bearing assembly into the bearing carrier until the bearing is seated. Mandrel Reverse gear Bearing Bearing carrier 17039 Bearing Mandrel Kit 91‑83166M Page 6A-30 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 437: Water Pump Base Reassembly
Slide the clutch onto the propeller shaft with the ring on the clutch facing toward the forward gear. Ensure that the hole in the clutch aligns with the slot in the propeller shaft. Clutch Ring faces toward forward gear Cross pin hole Slot 17044 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-31...
Page 438: Checking And Adjusting Pinion Gear Location
Install the propeller shaft assembly into the bearing carrier assembly. Propeller shaft assembly Thrust washer Bearing carrier assembly 16920 Checking and Adjusting Pinion Gear Location NOTE: Pinion gear height must be set prior to checking forward gear backlash. Page 6A-32 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 439 Step side (install toward pinion gear) 17053 Lift the driveshaft slightly and install the pinion gear. Thread the pinion nut onto driveshaft with the step side of the nut towards the pinion gear. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-33...
Page 440 Install the Pinion Height Tool into the forward gear bearing race. The flat side of the tool faces up when installed in the bearing race. NOTE: Take the following measurements at three locations, rotating the driveshaft 120 degrees between each reading. Rotate the driveshaft in a clockwise direction. Page 6A-34 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 441: Checking And Adjusting Forward Gear Backlash
Install the forward gear Backlash Preload Tool into the gearcase. Use a screwdriver to turn the tool shaft to apply light pressure against the forward gear assembly to prevent forward gear rotation. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-35...
Page 442 Part No. Loctite 271 Threadlocker Pinion nut threads 92-809819 Description lb. in. lb. ft. Pinion nut 10. Remove the Backlash Indicator Arm from the driveshaft. 11. Remove the Dial Indicator Assembly. Page 6A-36 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 443: Shift Shaft Installation
1.91–2.05 mm mm (0.075–0.081 in.) +0.50 mm (+0.020 in.) 2.06–2.25 mm (0.081–0.089 in.) +0.55 mm (+0.022 in.) Shift Shaft Installation Install the shift shaft with the bushing into the gearcase. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-37...
Page 444: Water Pump Cover Reassembly
Align the locating tab on top of the water pump liner with the slot in the water pump cover and insert the liner into the pump cover. Slot Water pump liner tab 17095 Install a new base plate gasket. Base plate gasket 21040 Page 6A-38 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 445 Install a new impeller and align with the drive key. Impeller Drive key 21037 Lubricate the inside circumference of the water pump liner with 2‑4‑C with PTFE. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-39...
Page 446: Propeller Shaft And Bearing Carrier Installation
Water pump cover screws Propeller Shaft and Bearing Carrier Installation Apply 2‑4‑C with PTFE to the bearing carrier O‑ring. Install the bearing carrier/propeller shaft assembly into the gearcase. Page 6A-40 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 447: Anode Inspection And Installation
For example ‑ if the boat turns more easily to the left, turn the trailing edge of the tab to the left. If the boat turns more easily to the right, turn the trailing edge of the tab to the right. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-41...
Page 448: Gear Housing Installation
Install the gearcase retaining screws, washers and nut. Tighten the screws, and the nut to the specified torque. Screws and washers (two each side) Nut and washer 21059 Page 6A-42 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 449 Reverse lock link (push up) Upper shift shaft Lower shift shaft Shift shaft coupler 22535 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 6A-43...
Page 450: Gearcase Lubricant Capacity
Gearcase Lubricant Capacity Gearcase lubricant capacity is approximately 350 ml (11.8 fl oz). Gearcase Lubricant Recommendation Mercury or Quicksilver Premium or High Performance Gear Lubricant. Checking Lubricant Level and Refilling Gearcase Place outboard in a vertical operating position. Remove vent plug.
Page 451: Propeller Installation
Place a block of wood between the propeller blade and the anti‑ventilation plate. To aid in the future removal of the propeller, liberally apply to the propeller shaft splines with one of the following Mercury/ Quicksilver products: Tube Ref No.
Page 453 Throttle Only Reassembly and Installation....7A-11 Tiller Handle Models............7A-8 Remote Control Models........... 7A-15 Throttle Only Operation..........7A-8 Shift Control Removal and Disassembly....7A-15 Neutral Safety Start Switch.........7A-8 Shift Control Assembly and Installation....7A-17 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7A-1...
Page 454 Measures RPM on spark ignition (SI) engines, ohms, amperes, AC and DC voltages; records maximums and minimums simultaneously, and accurately H z TEMP reads in high RFI environments. TEMP C O M 4516 Page 7A-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 456: Throttle And Steering Linkage Components
Throttle/Shift Linkage Throttle and Steering Linkage Components 19 20 16670 Page 7A-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 457 Clamp (remote control) Bolt (M6 x 16) (remote control) Drag link (remote control) Nut (remote control) 27.1 Washer (remote control) Spacer (remote control) Screw (remote control) Cap (remote control) Harness clamp 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7A-5...
Page 458: Shift And Cam Rod Components
Throttle/Shift Linkage Shift and Cam Rod Components 16669 Page 7A-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 459 Shift lever shaft (remote control) Shift arm (remote control) Bolt (remote control) Washer (remote control) Tube Ref No. Description Where Used Part No. 2-4-C with PTFE Shift detent, throttle only gears 92-802859A 1 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7A-7...
Page 460: Tiller Handle Models
Use a 19 mm open end wrench to hold the lower jam nut. Use a 14 mm open end wrench to rotate the neutral start safety switch counterclockwise to loosen. Slide the switch and actuator forward. Page 7A-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 461: Throttle Only Removal And Disassembly
Remove the two throttle rods from the throttle lever. Refer to Section 7B ‑ Tiller Handle Removal. Remove the throttle only button retainer clip from the cowl. Remove the retainer, grommet, and throttle only button. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7A-9...
Page 462 Shift detent Shift detent spring Bolt 18333 Disassembly Remove the three bolts from the gear plate halves. Separate the gear plates. Remove the nut from the drive gear assembly bolt. Page 7A-10 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 463: Throttle Only Reassembly And Installation
Throttle Only Reassembly and Installation Reassembly Install the spring and actuator into the shift lever shaft. While pushing on the actuator, install the retaining pin through the shaft. 11902 Actuator Spring Shift lever shaft 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7A-11...
Page 464 Throttle pulley Drive gear 18734 Install the bolt through the throttle lever components and the drive gear/gear plate. Bolt Washer Bushing Throttle opener Washer a b c Bushing Throttle pulley 18737 Page 7A-12 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 465 Position the shift lever shaft with reference to the shift detent as shown. NOTE: The illustration is for reference to show alignment of the shift lever shaft and the shift detent. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7A-13...
Page 466 Upper shift shaft installed in shift lever 18323 Install the throttle only assembly to the shift lever shaft. Attach the throttle only assembly to the powerhead with three bolts. Tighten the bolts to the specified torque. Page 7A-14 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 467: Remote Control Models
Remove the bolt securing the remote control cable clamp. Remove the cotter pins and washers on the remote control throttle and shift cables. Remove the cotter pins and washers on the shift rod. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7A-15...
Page 468 Harness clamp Throttle arm bracket Throttle arm bracket bolt (2) Remove the bolts securing the remote control bracket. Remote control bracket Remote control bracket bolt (2) Shift lever shaft 18898 Page 7A-16 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 469: Shift Control Assembly And Installation
Apply 2‑4‑C with PTFE to the end of the shift lever shaft that rotates in the shift lever shaft bracket. Bolt and washer Shift arm Remote control bracket Shift lever shaft 18911 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7A-17...
Page 470 Remote control bracket bolt (2) Shift lever shaft 18898 Description lb. in. lb. ft. Remote control bracket bolts (2) Install the throttle arm and bracket. Tighten the two bolts to the specified torque. Page 7A-18 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 471 12. Install the shift rod, throttle cable, and shift cable. 13. Install the cotter pins and washers on the shift rod. 14. Install the cotter pins and washers on the remote control throttle and shift cables. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7A-19...
Page 472 16. Install the remote control cables in the grommet. Install the grommet in the bottom cowl. 17. Install the bottom cowl cover. Tighten the three bolts to specified torque. 18863 Bolt (3) Bottom cowl cover Description lb. in. lb. ft. Bottom cowl cover bolts (3) Page 7A-20 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 473 Carry Handle/Tiller Handle........7B-21 Tiller Handle Removal............7B-10 Stop Wire Connections..........7B-22 Throttle Cables............7B-10 Throttle Cables............7B-22 Stop Wire Connections..........7B-11 Linkage and Grommet..........7B-23 Tiller Handle and Bracket......... 7B-11 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7B-1...
Page 474 Tiller Handle Lubricant, Sealant, Adhesives Tube Ref No. Description Where Used Part No. Loctite 271 Threadlocker Carry handle/tiller handle assembly mounting bolts 92-809819 Page 7B-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 476: Tiller Handle Components
Tiller Handle Tiller Handle Components 16665 Page 7B-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 477 Carry handle Bolt Washer Stop switch assembly Retainer Lanyard assembly Cover Screw Drive tight Screw Drive tight Tiller handle latch Button Collar Spring Washer Bushing Cover Bolt Bolt Throttle lock decal 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7B-5...
Page 478: Tiller Handle Operation
Rotate the tiller twist grip to the neutral position. Adjust the cable lengths using the jam nuts to bring match marks into alignment. • Make adjustments to the lower cable first. Page 7B-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 479: Linkage
Disconnect the power trim switch wires from the power trim relays. Refer to Section 5B ‑ Power Trim Electrical Circuit. Remove the three screws and the cover from the carry handle. Pry the power trim switch housing from the tiller handle. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7B-7...
Page 480 Loosen the power trim switch from the housing by pushing a thin blade screwdriver through the hole in the housing. Remove the power trim switch from the housing. 13953 Screwdriver Power trim switch housing Power trim switch Lock tab Page 7B-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 481: Installation
Power trim switch harness clamp Carry handle cover screw (3) 13952 Connect the power trim switch wires to the power trim relays. Refer to Section 5B ‑ Power Trim Electrical Circuit. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7B-9...
Page 482: Tiller Handle Removal
Remove both throttle cables from the bracket slots. Remove both cable ends from the pulley. NOTE: For easier installation, mark cables for respective position. 18095 Marks aligned in neutral position Control cable jam nuts Throttle opener Throttle rod Cotter pin and washer Throttle arm Page 7B-10 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 483: Stop Wire Connections
Carry handle bracket 18099 Tiller Handle Disassembly Remove the three screws securing the cover to the carry handle. Carry handle cover screws Tiller handle Carry handle Wire harness and cables 13813 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7B-11...
Page 484 Separate the tiller handle and carry handle while pulling the throttle cable ends and tiller handle stop switch wires through the carry handle. Carry handle Tiller handle 13875 Remove the screw from the throttle shaft bracket. Remove the throttle shaft bracket. Loosen the throttle shaft friction control knob. Page 7B-12 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 485 Rubber grip 2997 13. Remove the stop button and wires. 14. Remove the throttle shaft friction control knob assembly. Stop button/wire assembly Throttle shaft friction control knob and clamp assembly 2998 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7B-13...
Page 486: Throttle Cable Case
Pulley Cover Cables Screw and washer Assembly Install cable end barrel into slot on pulley. Throttle cable Cable end barrel in slot Pulley 3009 Install pulley with cables into case. Page 7B-14 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 487: Tiller Handle Assembly
Rotate pulley and ensure that cables move freely in the correct direction. 2967 Forward throttle cable Reverse throttle cable Tiller Handle Assembly Install the throttle handle onto the throttle shaft. 3016 Throttle shaft Throttle handle 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7B-15...
Page 488 Feed the stop button wires through the throttle cable pulley housing. Install the throttle cable pulley housing into the tiller handle. Install the throttle handle assembly onto the tiller handle. Page 7B-16 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 489 11. Insert the throttle shaft into the throttle cable pulley housing. 12. Route the stop button wires around the notch in the throttle cable pulley housing. 13. Install a washer and bushing on the tiller handle. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7B-17...
Page 490 15. Guide the cables and the stop button wire through the hole in the carry handle. Align the cables and stop button wire in the carry handle channel and through the opening in the carry handle. 16. Attach the tiller handle to the carry handle. Carry handle Rubber washer Bushing Tiller handle 13859 Page 7B-18 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 491 19. Assemble the tiller handle latch and spring into the carry handle. Ensure that the other spring tang is positioned as shown. Tiller handle latch Spring Spring tang Carry handle support wall 13872 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7B-19...
Page 492: Shift/Throttle Cable Position Reference
NOTE: The term forward cable and reverse cable refers to the control cable that is pulling to shift the outboard in that direction. Forward Reverse cable Reverse cable end Forward cable Throttle rod Throttle rod 18153 Page 7B-20 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 493: Tiller Handle Installation
18099 Tube Ref No. Description Where Used Part No. Loctite 271 Threadlocker Carry handle/tiller handle assembly mounting bolts 92-809819 Description lb. in. lb. ft. Tiller handle assembly mounting bolts 22.1 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7B-21...
Page 494: Stop Wire Connections
Rotate the tiller twist grip counterclockwise until the reverse cable slot in the pulley is near the top. Install the forward cable end in the forward cable slot in the pulley. Page 7B-22 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 495: Linkage And Grommet
Forward cable Reverse cable end Forward cable end 18158 10. Adjust the shift/throttle cables. Refer to Throttle Cable/Linkage Adjustments preceding. Linkage and Grommet Install the throttle rod to the throttle opener. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7B-23...
Page 496 Route the lanyard stop switch and tiller handle stop button wires and shift/throttle cables through the grommet. Install the lower cowl cover. Lanyard stop switch and tiller handle stop button wires Reverse shift/throttle cable Forward shift/throttle cable Grommet Lower cowl cover 18104 Page 7B-24 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 497 Install the three lower cowl cover attaching screws. Tighten the screws to the specified torque. 18093 Lower cowl cover screw (2) Grommet Lower cowl cover screw (1) Lower cowl cover Description lb. in. lb. ft. Lower cowl cover screws 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 7B-25...
Page 499 Section 8A - Recoil Starter Table of Contents Recoil Starter Components..........8A-4 Recoil Starter Assembly..........8A-8 Recoil Starter..............8A-6 Recoil Starter Installation..........8A-12 Recoil Starter Removal..........8A-6 Neutral Interlock Cable Adjustment......8A-13 Recoil Starter Disassembly.........8A-7 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 8A-1...
Page 500 Where Used Part No. Loctite 271 Threadlocker Threads of the friction plate retaining bolt 92-809819 Recoil housing 2-4-C with PTFE Starter pawl bore on the recoil sheave 92-802859A 1 Friction plate Page 8A-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 502: Recoil Starter Components
Recoil Starter Recoil Starter Components 16664 Page 8A-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 503: Recoil Starter
Seal Bolt Washer Starter lock cam spring Lock cable Belt cover Collar Bracket Screw (M6 x 16) Bolt Washer Collar Bolt Decal ‑ Spark plug (with resistance) Decal ‑ Caution 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 8A-5...
Page 504: Recoil Starter Removal
Remove the timing belt cover. Do not lose the T‑nuts located in the recoil housing assembly. 20513 Pull the neutral interlock cable to disengage the neutral interlock cable from the recoil housing. Page 8A-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 505: Recoil Starter Disassembly
Bolt securing recoil friction plate Rotate recoil sheave clockwise 9719 Carefully remove the recoil starter sheave. Remove the recoil spring if replacement is needed. Disengage the interlock lever spring from the recoil lock. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 8A-7...
Page 506: Recoil Starter Assembly
92-802859A 1 Tie a knot on one side of the recoil rope and insert the recoil rope through the recoil sheave. Thread the recoil rope through the recoil sheave as shown. Page 8A-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 507 Tube Ref No. Description Where Used Part No. 2-4-C with PTFE Starter pawl bore on the recoil sheave 92-802859A 1 10. Secure starter pawl with the E‑ring retained during disassembly. 9725 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 8A-9...
Page 508 Threads of the friction plate retaining bolt 92-809819 18. Insert the recoil rope into the guide and through the recoil housing. 19. Insert the rope end through the recoil handle. Page 8A-10 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 509 24. Ensure the recoil rope retracts and extends fully. 25. Insert the recoil lock into the recoil housing. 26. Push the recoil lock until it snaps into place. Recoil lock Recoil sheave Recoil lock bore 9749 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 8A-11...
Page 510: Recoil Starter Installation
Install the timing belt cover. Ensure the aft mounting of the timing belt cover is supported by two spacers. Align the harness connector bracket with the timing belt cover and install a bolt. Do not tighten the bolts at this time. Page 8A-12 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 511: Neutral Interlock Cable Adjustment
Recoil retaining bolts (3) Timing belt cover retaining bolts (4) Neutral Interlock Cable Adjustment Ensure the tiller handle control cables are properly adjusted. Ensure the tiller handle is in neutral. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 8A-13...
Page 512 Throttle cam Interlock cable nuts 22639 Adjust the interlock cable nuts so the neutral interlock cable ball is centered on the recoil lock. Neutral interlock cable ball Recoil lock 22640 Page 8A-14 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 513 Water Pump Disassembly........9A-14 Shift Cam Adjustment (Tiller Models)......9A-22 Bearing Carrier Removal.......... 9A-14 Shift Cam Adjustment (Remote Control Models)..... 9A-23 Liner Removal............9A-14 Neutral Interlock Cable (Remote Models)......9A-24 Jet Drive Reassembly............9A-15 Installation..............9A-24 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 9A-1...
Page 514 Bearing carrier mounting screw threads Loctite 271 Threadlocker 92-809819 Jet drive mounting bolt threads Inside pump liner housing Liner mounting bolts threads 2-4-C with PTFE 92-802859A 1 Driveshaft splines Driveshaft and impeller bore Page 9A-2 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 516: Jet Unit Components
Jet Drive Outboard Jet Unit Components 26149 Page 9A-4 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 517 Driveshaft Sleeve Bolt Bolt Washer Impeller Shim Tab washer Intake housing assembly Liner Anode kit Bolt (M6 x 25) Washer Bolt (M6 x 16) 11.3 Bolt (M6 x 20) 11.3 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 9A-5...
Page 518: Jet Water Pump Components
Jet Drive Outboard Jet Water Pump Components 25828 Page 9A-6 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 519 Jet Water Pump Components Torque Ref. No. Qty. Description lb. in. lb. ft. Grommet Water tube Seal Bolt Washer Housing Pump liner Impeller Gasket Guide plate Gasket Housing Dowel pin 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 9A-7...
Page 520: Shift Linkage Components - Jet Tiller Handle
Jet Drive Outboard Shift Linkage Components ‑ Jet Tiller Handle 25934 Page 9A-8 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 521 Ref. No. Qty. Description lb. in. lb. ft. Retainer Washer Spring Retainer Bushing Seal Washer Bolt and washer Plate Shift lever Clip Lockwasher Spring Shift rod Link rod Link rod 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 9A-9...
Page 522: Shift Linkage Components - Jet Remote Control
Jet Drive Outboard Shift Linkage Components ‑ Jet Remote Control 26151 Page 9A-10 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 523 Shift Linkage Components - Jet Remote Control Torque Ref. No. Qty. Description lb. in. lb. ft. Screw Washer Clamp Bracket Bolt (M6 x 16) Washer Bolt Bracket Bolt (M6 x 16) Lockwasher Pivot bolt Washer Clip 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 9A-11...
Page 524: Water Testing
Remove the six mounting bolts securing the water intake housing and remove the water intake housing. Mounting bolts Water intake housing 25729 Straighten the bent tabs on the nut retainer and remove the impeller nut. Page 9A-12 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 525 Impeller Shear key Shims Nut retainer Impeller nut 25730 Remove the five bolts securing the jet drive to the driveshaft housing. Remove the jet drive. 25731 Bolt (4) Bolt (1) 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 9A-13...
Page 526: Water Pump Disassembly
Remove the two screws securing the bearing carrier to the jet drive. Remove the bearing carrier. Screws Bearing carrier 25763 Liner Removal Mark the mounting bolts for reassembly into the same holes. Remove the two mounting bolts. Page 9A-14 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 527: Jet Drive Reassembly
Screws Bearing carrier 25763 Tube Ref No. Description Where Used Part No. Loctite 271 Threadlocker Bearing carrier mounting screw threads 92-809819 Description lb. in. lb. ft. Bearing carrier mounting screws 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 9A-15...
Page 528: Water Pump Installation
Inside pump liner housing 92-802859A 1 Description lb. in. lb. ft. Water pump cover screws Liner Installation Locate the holes in the liner with holes in the water intake housing. Page 9A-16 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 529: Jet Drive Installation
Install the jet drive to the driveshaft housing with the five bolts shown. Apply Loctite 271 Threadlocker to the bolt threads and tighten the bolts to the specified torque. 25731 Lower bolts (4) Upper bolt (1) 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 9A-17...
Page 530 0.76 mm (0.03 in.). Shim washers can be transferred to either side of the impeller to raise or lower the impeller to the correct clearance setting. Shim washers Impeller clearance 25824 Jet Drive Clearance between impeller and liner 0.76 mm (0.03 in.) Page 9A-18 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 531 Tube Ref No. Description Where Used Part No. Mounting flange on the water intake housing, mounting bolt Extreme Grease 8M0071842 threads Description lb. in. lb. ft. Water intake housing mounting bolts 11.3 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 9A-19...
Page 532: Shift Lever Removal And Installation (Tiller Models)
Shift lever 25872 Push back the spring‑loaded stopper to expose the cross pin. Remove the cross pin and slide the shift lever out of the bottom cowl. Cross pin Stopper 25874 Page 9A-20 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 533: Shift Lever Installation
Center the cross pin and rotate the stopper so it fits over the cross pin. Cross pin Stopper 25874 Fasten the bushing to the bottom cowl with the retainer. Retainer Shift lever 25872 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 9A-21...
Page 534: Shift Link Rod Removal And Installation (Tiller Models)
This can cause serious injury or death from occupants being thrown within or out of the boat. Adjust the shift cable to prevent the reverse gate from interfering with water flow off the rudder. Page 9A-22 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 535: Shift Cam Adjustment (Remote Control Models)
The reverse gate should not move when pushed toward the neutral position. IMPORTANT: The forward locking of the reverse gate must be met. If not, readjust the shift cable. 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 9A-23...
Page 536: Neutral Interlock Cable (Remote Models)
Route the cable behind the electrical cover and out through the rubber grommet in the bottom cowl. Neutral interlock cable Electrical cover 25973 Rubber grommet Neutral interlock cable 25972 Fasten the cable to the skirt on the starboard side with a clamp. Page 9A-24 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 537 Position the remote control handle into neutral position. Adjust the cable nuts so the neutral interlock cable ball is centered on the recoil lock. Tighten the nuts. Cable nuts 25977 90-8M0105568 eng MARCH 2016 © 2016 Mercury Marine Page 9A-25...
Page 538 Jet Drive Outboard Neutral interlock cable ball Recoil lock 22640 Shift the outboard from forward to reverse several times. Check the neutral interlock function in the forward, reverse, and neutral positions. Page 9A-26 © 2016 Mercury Marine 90-8M0105568 eng MARCH 2016...
Page 540 Parc Industriel de Petit-Rechain 41-71 Bessemer Drive P.O. Box 1939 B-4800 Verviers, Belgium Dandenong South, Victoria 3175 Australia Fond du Lac, WI 54936-1939 USA © Mercury Marine. All rights reserved. 90-8M0105568 MARCH 2016 Printed in U.S.A.

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