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Table of Contents
- 1 Boat Horsepower Capacity
- 2 Start-In-Gear Protection
- 3 Selecting Accessories for the Outboard
- 4 Installation Specifications
- 5 Lifting Outboard
- 6 Steering Cable
- 7 Steering Link Rod
- 8 Installation Note
- 9 Installing Outboard
- 10 Determining Recommended Outboard Mounting Height
- 11 Electrical, Hoses, and Control Cables
- 12 Remote Wiring Harness
- 13 Fuel Hose
- 14 Propeller Installation
- 15 Trim-In Stop Adjustment
- 16 Trim Tab Adjustment
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75, 90 AND 115 HP (4-Stroke)
NOTICE TO INSTALLER: After completing assembly, these instructions should be
placed with the product for the owner's future use.
IMPORTANT: If the boat is to be water tested, the operator should be familiar with the
operation procedures in the Operation and Maintenance Manual.
Electric Fuel Pump
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Boat Horsepower Capacity
Start in Gear Protection
Selecting Accessories For The Outboard
Installation Specifications
Lifting Outboard
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Cable
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Link Rod
. . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Outboard
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Electrical, Hoses and Control Cables
Front Cowl Grommet
Electric Fuel Pump
If an electric fuel pump is used, the fuel pressure must not exceed 4 psig at the engine. If
necessary, install a pressure regulator to regulate the pressure.
Boat Horsepower Capacity
Do not overpower or overload the boat. Most boats will carry a required capacity plate indi-
cating the maximum acceptable power and load as determined by the manufacturer follow-
ing certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer.
Using an outboard that exceeds the maximum horsepower limit of a boat can:
1. cause loss of boat control 2. place too much weight at the transom, altering
the designed flotation characteristics of the boat or 3. cause the boat to break
apart, particularly around the transom area. Overpowering a boat can result in
serious injury, death, or boat damage.
90-10216040 JANUARY 2003
INSTALLATION MANUAL
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U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER
MAXIMUM PERSON
CAPACITY (POUNDS)
MAXIMUM WEIGHT
CAPACITY
Printed in U.S.A. -
1
Remote Wiring Harness
1
Battery Cable Connections
2
Fuel Hose
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2
Speedometer (Optional) Water Pick-up
2
75 and 90 Hp Shift Cable Installation
3
75 and 90 Hp Throttle Cable Installation
3
115 Hp Shift Cable Installation
4
115 Hp Throttle Cable Installation
5
Propeller Installation
7
Trim-In Stop Adjustment
7
Trim Tab Adjustment
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WARNING
2003, Mercury Marine
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Summary of Contents for Mercury 75 HP
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Page 1: Boat Horsepower Capacity
3. cause the boat to break apart, particularly around the transom area. Overpowering a boat can result in serious injury, death, or boat damage. 90-10216040 JANUARY 2003 Printed in U.S.A. - 2003, Mercury Marine Page 1 of 18... -
Page 2: Start-In-Gear Protection
75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Start in Gear Protection The remote control connected to the outboard must be equipped with a start-in-gear protection device. This prevents the engine from starting in gear. WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engine. -
Page 3: Lifting Outboard
75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Lifting Outboard Use Flywheel Puller/Lifting Eye (91-83164M). Steering Cable STARBOARD SIDE ROUTED CABLE 1. Lubricate O-ring seal and entire cable end. Quicksilver 2-4-C Marine Lubricant with Teflon 2. Insert steering cable into tilt tube. 3. -
Page 4: Steering Link Rod
75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Steering Link Rod Installation Note NOTE: For ease of installation of special bolt (a) separate the front end of the bottom cowl. 1. Install steering link rod per illustration. Special Bolt (10-90041) Torque to 20 lb. ft. (27.1 N·m) Nylon Insert Locknut (11-34863) Torque to 20 lb. -
Page 5: Installing Outboard
75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Installing Outboard Determining Recommended Outboard Mounting Height 26 in. (660mm) 25 in. (635mm) 24 in. (609mm) 23 in. Outboard (584mm) Mounting Height 22 in. (See NOTE (560mm) Below) 21 in. (533mm) 20 in. (508mm) 19 in. - Page 6 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Installing Outboard 1. Use transom drilling fixture (91-98234A2) or attach (tape) engine mounting template (located in this manual) to boat transom. 2. Mark and drill four 17/32 in. (13.5mm) mounting holes. 3. Refer to “Determining Recommended Outboard Motor Mounting Height”, preceding, and install outboard to the nearest recommended mounting height.
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Page 7: Electrical, Hoses, And Control Cables
75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Electrical, Hoses, and Control Cables IMPORTANT: Warning Horn Requirement – The remote control or key switch assembly must be wired with a warning horn. This warning horn is used with the engine warning system. Front Cowl Grommet Pull up the cowl seal and remove the cover from the bottom cowl. - Page 8 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Battery Cable Connections SINGLE OUTBOARD (–) Red Sleeve (Positive) Black Sleeve (Negative) Starting Battery DUAL OUTBOARDS Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. (–) (–) Ground Cable (Same Wire Size As Engine Battery Cable) –...
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Page 9: Fuel Hose
75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Fuel Hose PORTABLE FUEL TANK Select a suitable location in boat within engine fuel line length limitations and secure tank in place. PERMANENT FUEL TANK These should be installed in accordance with industry and federal safety standards which include recommendations applicable to grounding, anti-siphon protection, ventilation, etc. - Page 10 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL 75 and 90 Hp Shift Cable Installation Install cables into the remote control following the instructions provided with the remote control. NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral.
- Page 11 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL 4. Position remote control into neutral. 5. Align the shift cable end guide with the center point made in Step 2. Place shift cable on anchor pin. Adjust cable barrel so it slips freely into the barrel holder. 6.
- Page 12 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL 75 and 90 Hp Throttle Cable Installation Install cables into the remote control following the instructions provided with the remote control. 1. Position remote control into neutral. 2. Install throttle cable to the throttle arm with hairpin cotter. 3.
- Page 13 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL 115 Hp Shift Cable Installation Install cables into the remote control following the instructions provided with the remote control. NOTE: Install the shift cable to the engine first. The shift cable is the first cable to move when the remote control handle is moved out of neutral.
- Page 14 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL 4. Position remote control into neutral. 5. Align the shift cable end guide with the center point made in Step 2. Place shift cable on anchor pin. Adjust cable barrel so it slips freely into the barrel holder. 6.
- Page 15 75, 90 and 115 (4-STROKE) INSTALLATION MANUAL 115 Hp Throttle Cable Installation Install cables into the remote control following the instructions provided with the remote control. 1. Position remote control into neutral. 2. Install throttle cable to the throttle arm with hairpin cotter. 3.
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Page 16: Propeller Installation
75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Propeller Installation WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine start- ing and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller. -
Page 17: Trim-In Stop Adjustment
75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Trim-In Stop Adjustment Some outboard boats, particularly some bass boats, are built with a greater than normal transom angle which will allow the outboard to be trimmed further “in” or “under”. This great- er trim “under”... -
Page 18: Trim Tab Adjustment
75, 90 and 115 (4-STROKE) INSTALLATION MANUAL Trim Tab Adjustment The trim tab can be adjusted within limits to help compensate for steering torque. Adjust trim tab as follows: 1. If boat tends to pull to the right, move the rear edge of the trim tab to the right. 2.