Mercury 100 EFI Owner's Manual
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Mercury 100 EFI Owner's Manual

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Download this manual See also: Operation & Maintenance Manual, User Manual
Welcome Aboard!
Proper care and maintenance is an important part in keeping your Mercury Product operating at peak
efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key
to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty
coverage.
Details of your nearest dealer can be found on www.marinepower.com where country maps and full
contact information are displayed.
Is your engine properly registered for warranty purpose? Please check on www.marinepower.com. If
necessary, please contact your local dealer.

Declaration of Conformity

This outboard motor's serial number plate contains in the lower corner left hand corner either the CE
mark alone or the CE mark accompanied by a notified body number. This outboard motor manufactured
by Mercury Marine, Fond du Lac, WI, USA or Marine Power Europe Inc. Park Industriel, de Petit-Rechain,
Belgium complies with the requirements of the following directives by meeting the associated standards,
as amended:
If the CE mark is accompanied by a notified body number, the following Recreational Craft Directive
applies:
Recreational Craft Directive:
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engine starting (A.5.1.4)
Fuel tanks (A.5.2.2)
General steering system
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
The notified body responsible for surveillance of the quality system under Full
Quality Assurance Module H of Directive 2003/44/EC is:
Det Norske Veritas
Norway
Notified Body Number: 0575
If the CE mark is not accompanied by a notified body number, the following Recreational Craft Directive
language applies:
Recreational Craft Directive:
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engine starting (A.5.1.4)
2003/44/EC amending 94/25/EC
ISO 10240
ISO 8665
ISO 11547
ISO 13591; ISO 8469
ABYC P-17
ISO 8178
ISO 8665
ISO 14509
ISO 10240
ISO 8665
ISO 11547
i
94/25/EC

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  • Page 1: Declaration Of Conformity

    CE mark accompanied by a notified body number. This outboard motor manufactured by Mercury Marine, Fond du Lac, WI, USA or Marine Power Europe Inc. Park Industriel, de Petit-Rechain, Belgium complies with the requirements of the following directives by meeting the associated standards,...
  • Page 2 EN 61000-6-2; EN 61000-4-2; EN Electrostatic discharge testing 61000-4-3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe. Patrick C. Mackey President, Mercury Marine, Fond du Lac, WI USA European Regulations Contact: Regulations and Product Safety Department, Mercury Marine,...

  • Page 3: Table Of Contents

    Impact With Underwater Hazards........................14 Exhaust Emissions............................15 Selecting Accessories For Your Outboard......................16 Safe Boating Suggestions..........................16 Recording Serial Number..........................17 80/100/115 Specifications - International......................17 Component Identification..........................19 Transporting Trailering Boat/Outboard........................... 20 Fuel and Oil Fuel Recommendations............................ 21 Filling Fuel Tank..............................
  • Page 4 TABLE OF CONTENTS Operation Pre-Starting Check List............................. 30 Operating In Freezing Temperatures........................ 30 Operating In Salt Water Or Polluted Water....................... 30 Setting Trim Angle while Running Engine at Idle Speed.................. 30 Engine Break-in Procedure..........................31 Starting The Engine - Remote Control Models....................31 Gear Shifting..............................
  • Page 5 Owner Service Assistance Local Repair Service............................60 Service Away From Home..........................60 Parts And Accessories Inquiries........................60 Service Assistance............................60 Mercury Marine Service Offices........................60 Outboard Installation Important Information............................62 Boat Horsepower Capacity..........................62 Start in Gear Protection............................ 62 Selecting Accessories For Your Outboard......................62 Fuel Tanks................................

  • Page 7: Warranty Information

    You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department. Your dealer can also process this change of information.

  • Page 8: Fourstroke Outboard Limited Warranty United States, Canada And Europe

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/ or travel time.

  • Page 9: Fourstroke Outboard Limited Warranty

    FourStroke Outboard Limited Warranty (Confederation of Independent States, Middle-East, and Africa WHAT IS COVERED: Mercury Marine warrants its new Outboard and Jet Products to be free of defects in material and workmanship during the period described below. DURATION OF COVERAGE: This Limited Warranty provides coverage for one (1) year from the date the product is first sold to a recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs first.
  • Page 10 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/ or travel time.

  • Page 11: Year Limited Warranty Against Corrosion

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/ or travel time.

  • Page 12: Warranty Coverage And Exclusions

    Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti-fouling paints is also not covered by this limited warranty.
  • Page 13 All incidental and/or consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time or income) are the owner's responsibility. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.

  • Page 14: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard. Be sure at least one additional person on board is instructed in the basics of starting and operating the outboard and boat handling in case the driver is unable to operate the boat.

  • Page 15: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our Hi-Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. ob00307 Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device.

  • Page 16: Outboard Mounting Notice

    GENERAL INFORMATION WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. ob00655 Self-locking nuts Outboard Mounting Notice WARNING Before operation, the outboard must be correctly installed with the required mounting hardware as shown.

  • Page 17: Lanyard Stop Switch

    GENERAL INFORMATION 22551 If changing conditions cause the RPM to drop below the recommended range, such as warmer, more humid weather, operation at higher elevations, increased boat load, or a dirty boat bottom/gearcase, a propeller change or cleaning may be required to maintain performance and ensure the outboards durability. Check full-throttle RPM, using an accurate tachometer, with the engine trimmed out to a balanced-steering condition (steering effort equal in both directions) without causing the propeller to break loose.

  • Page 18: Protecting People In The Water

    GENERAL INFORMATION We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency (e.g. if the operator is accidentally ejected). WARNING Should the operator fall out of the boat, the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately.

  • Page 19: Boats Having An Open Front Deck

    GENERAL INFORMATION Passenger Safety Message - Pontoon Boats And Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the boat.

  • Page 20: Impact With Underwater Hazards

    GENERAL INFORMATION ob00314 The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may cause the boat to veer violently in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats, or out of the boat.

  • Page 21: Exhaust Emissions

    GENERAL INFORMATION • The boat could move suddenly in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat. • A rapid reduction in speed. This will cause occupants to be thrown forward, or even out of the boat. •...

  • Page 22: 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 23: Recording Serial Number

    It is important to record this number for future reference. The serial number is located on the outboard as shown. XXXXXXXX XXXX XXXX 20880 Serial number Year manufactured Model year Certified Europe Insignia (as applicable) Model designation 80/100/115 Specifications - International Models 80/100/115 Horsepower 80/100/115...
  • Page 24 GENERAL INFORMATION Models 80/100/115 Kilowatts 60/75/86 80/100 HP - 5000-6000 Full Throttle RPM Range 115HP - 5800-6400 700 RPM Idle Speed in Neutral Gear Number of Cylinders Piston Displacement 1,731 cc (105.6 cid) Cylinder Bore 82 mm (3.23 in.) Stroke 82 mm (3.23 in.)

  • Page 25: Component Identification

    GENERAL INFORMATION Component Identification 20784 Top cowl Trim tab Bottom cowl Auxiliary tilt switch Water pump indicator hole Transom brackets Driveshaft housing Cooling water intake holes Anti-ventilation plate Gearcase...

  • Page 26: Transporting

    TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways, and trailer bouncing.

  • Page 27: Fuel And Oil

    The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 28: Filling Fuel Tank

    NMMA FC-W certified 4-Stroke Outboard Oil of similar viscosity may be used. IMPORTANT: The use of non-detergent oils, multi-viscosity oils (other than Mercury or Quicksilver NMMA FC- W certified oil or a major brand NMMA FC-W certified oil), synthetic oils, low quality oils or oils that contain solid additives are not recommended.
  • Page 29 FUEL AND OIL IMPORTANT: Do not try to fill the oil level to the top of the operating range (cross hatched region). Oil level is correct as long as it appears in the operating range (cross hatched region). 20712 Oil level operating range If the oil level is below the operating range (cross hatched region), remove the oil filler cap and add approximately 500 ml (16 oz.) of the specified outboard motor oil.

  • Page 30: Features And Controls

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. ob00329 Control handle - forward, neutral, reverse.
  • Page 31 FEATURES AND CONTROLS Warning Horn Function Sound Description Cooling system problem Continuous Engine Guardian System is activated. Power limit will vary with level of overheat. Shift outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole.

  • Page 32: Power Trim And Tilt

    SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel consumption and engine operating hours.

  • Page 33: Power Trim Operation

    FEATURES AND CONTROLS 20760 Trim switch Trim range Tilt range POWER TRIM OPERATION With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out.
  • Page 34 FEATURES AND CONTROLS • In rare circumstances, the owner may decide to limit the trim in. This can be accomplished by purchasing a stainless steel tilt pin from your dealer and inserting it in whatever adjustment hole in the transom brackets is desired. The non-stainless steel shipping bolt should not be used in this application other than on a temporary basis.

  • Page 35: Auxiliary Tilt Switch

    FEATURES AND CONTROLS AUXILIARY TILT SWITCH This switch can be used to tilt the outboard up or down using the power trim system. 20886 Auxiliary tilt switch SHALLOW WATER OPERATION When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom.

  • Page 36: Pre-Starting Check List

    Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.

  • Page 37: Engine Break-In Procedure

    OPERATION 20776 Relief hole submerged (wrong) Relief hole above water line (correct) Engine Break-in Procedure CAUTION Severe damage to the engine can result by not complying with the Engine Break-in Procedure. For the first two hours of operation, run the engine at varied throttle settings up to 4500 RPM or at three- quarter throttle, and at full throttle for approximately one minute every ten minutes.
  • Page 38 OPERATION 20765 Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 Set the lanyard stop switch to RUN position. Refer to General Information - Lanyard Stop Switch. 19791 Shift outboard to neutral (N) position. ob00351 NOTE: For initial start of a new engine or for an engine that ran out of fuel or was drained of fuel, the fuel system should be filled as follows:...

  • Page 39: Warming Up Engine

    OPERATION 19804 After engine starts, check for a steady stream of water flowing out of the water pump indicator hole. 20766 IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake for obstruction.
  • Page 40 OPERATION ob00360...

  • Page 41: Maintenance

    SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. WARNING Using a replacement part that is inferior to the original part could result in personal injury, death, or product failure.

  • Page 42: Inspection And Maintenance Schedule

    MAINTENANCE Inspection and Maintenance Schedule BEFORE EACH USE • Check engine oil level. See Fuel and Oil - Checking and Adding Engine Oil. • Check that lanyard stop switch stops the engine. • Visually inspect the fuel system for deterioration or leaks. •...

  • Page 43: Flushing The Cooling System

    MAINTENANCE • Replace high pressure in-line fuel filter. • Replace spark plugs after the first 300 hours or three years. After that, inspect spark plugs every 300 hours or three years. Replace spark plugs as needed. See Spark Plug Inspection and Replacement. •...

  • Page 44: Flywheel Cover Removal And Installation

    MAINTENANCE 20739 Pull down the rear cowl latch. Remove the top cowl. 20741 INSTALLATION Lower the top cowl into position over the engine. Pull up the rear cowl latch to lock down the rear. Push in the front cowl latch to lock down the front. Flywheel Cover Removal and Installation REMOVAL Lift the cover off the rear mounting pin and slide the cover forward to release the cover from the front mounting...

  • Page 45: Cleaning Care For Top And Bottom Cowls

    Keep water spray out of the air filter/intake and alternator. After washing, allow the powerhead and components to dry. Apply Quicksilver or Mercury Precision Lubricants Corrosion Guard spray on the external metal surfaces of the powerhead and powerhead components. Do not allow the Corrosion Guard spray to come in contact with the alternator drive belt or belt pulleys.

  • Page 46: Battery Inspection

    MAINTENANCE Tube Ref No. Description Where Used Part No. External metal surfaces of the powerhead and Corrosion Guard 92-802878Q55 powerhead components. Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability. IMPORTANT: Read the safety and maintenance instructions which accompany your battery. Turn off the engine before servicing the battery.

  • Page 47: Fuel System

    MAINTENANCE 20817 Purge vent tube Bottom tab AIR FILTER ASSEMBLY INSTALLATION Place the air filter assembly over the air intake as shown and then push the air filter assembly onto the air intake until it is fully seated. Reconnect the breather tube and purge vent tube to the air filter. Fuel System WARNING Avoid serious injury or death from gasoline fire or explosion.

  • Page 48: High Pressure Fuel Filter

    MAINTENANCE 20808 Low pressure fuel filter High pressure fuel filter HIGH PRESSURE FUEL FILTER The high pressure fuel filter is under high pressure. A special tool and procedure is required to release the fuel pressure before the filter can be removed. Have the high pressure fuel filter serviced by an authorized dealer. LOW PRESSURE FUEL FILTER Removal Turn ignition key switch to "OFF"...
  • Page 49 MAINTENANCE CAUTION Fuel vapor vent system is under pressure. Cover valve assembly with a rag or towel to prevent fuel or fuel vapor spray. Relieve pressure slowly. Place a rag or towel around the valve, and release the fuel pressure by pushing the core of the valve end 13282 Push in on the fuel hose release tabs and disconnect the fuel hoses from the fuel filter.

  • Page 50: Corrosion Control Anode

    MAINTENANCE 20888 Fuel hose retainer Visually inspect for fuel leakage from the fuel filter while turning the ignition key to "RUN" position, forcing fuel into the fuel filter. Repair any fuel leaks if necessary. Corrosion Control Anode The outboard has corrosion control anodes at different locations. An anode helps protect the outboard against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard metals.
  • Page 51 Place a block of wood between gearcase and propeller to hold propeller and remove propeller nut. ob00377 Pull propeller straight off shaft. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4- C with Teflon. ob00378 Tube Ref No.
  • Page 52 MAINTENANCE IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft, especially in salt water, always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed. Flo-Torq I Drive Hub Propellers - Install thrust washer, propeller, continuity washer, thrust hub, propeller nut retainer, and propeller nut onto the shaft.

  • Page 53: Spark Plug Inspection And Replacement

    MAINTENANCE Secure propeller nut by bending three of the tabs into the thrust hub grooves. ob00422 10. Reinstall spark plug leads. Spark Plug Inspection and Replacement Remove top cowling. Refer to Top Cowl Removal and Installation. Disconnect the wiring harness connectors from the pencil coils. Remove the mounting bolts that are securing the pencil coils.

  • Page 54: Fuse Replacement

    MAINTENANCE ob00680 Spark Plug Spark Plug Gap 0.8 mm (0.032 in.) Saltwater use - Apply a thin coating of Anti-Seize Compound only on threads of spark plugs. Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger tight, and then tighten 1/4 turn or torque to specifications.

  • Page 55: Alternator Drive Belt Inspection

    MAINTENANCE 20819 Good fuse Electric fuel pump - 20 AMP fuse Blown fuse Ignition coils - 20 AMP fuse Diagnostics terminal - 2 AMP fuse Spare fuse - 20 AMP fuse 14 pin remote control harness/cowl trim Fuel injectors/purge valve/idle air control - 20 switch/main power relay - 15 AMP fuse AMP fuse SmartCraft data bus circuit - 5 AMP fuse...

  • Page 56: Lubrication Points

    Propeller Shaft - Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. ob00378 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C with Teflon or Special Lubricant 101. Tube Ref No. Description Where Used Part No.
  • Page 57 MAINTENANCE ob00683 Swivel bracket Tilt support lever • Tilt Tube - Lubricate through fitting. ob00684 • Steering Cable Grease Fitting (If equipped) - Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube. Lubricate through fitting. ob00685 Fitting Steering cable end...

  • Page 58: Checking Power Trim Fluid

    Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricants Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.
  • Page 59 MAINTENANCE ob00436 CHANGING OIL FILTER Place a rag or towel below the oil filter to absorb any spilled oil. Unscrew old filter by turning the filter to the left. 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 60: Gearcase Lubrication

    Place a drain pan below outboard. Remove vent plugs and fill/drain plug and drain lubricant. ob00441 Vent plugs Fill/drain plug GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 666 ml (22.5 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant.

  • Page 61: Submerged Outboard

    MAINTENANCE CHECKING LUBRICANT LEVEL AND FILLING GEARCASE Place outboard in a vertical operating position. Remove the front vent plug and rear vent plug. Remove fill/drain plug. Place lubricant tube into the fill/drain plug hole and add lubricant until it appears at the front vent hole.

  • Page 62: Storage

    & Stabilizer Protecting External Outboard Components • Touch up any paint nicks. See your dealer for touch-up paint. • 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 63: Gearcase

    STORAGE Tube Ref No. Description Where Used Part No. Storage Seal Rust Spark plug holes 92-802878Q56 Inhibitor • Actuate key/push button start switch to crank the engine through one start cycle, which will distribute the storage seal throughout the cylinders. •...

  • Page 64: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Lanyard stop switch not in "RUN" position. • Blown 15 AMP fuse. Check 14 pin remote control harness/cowl trim switch/main power relay fuse. Refer to Maintenance section. • Outboard is not shifted to neutral position. •...

  • Page 65: Battery Will Not Hold Charge

    TROUBLESHOOTING • Damaged propeller or improper propeller size. • Incorrect engine timing, adjustment, or setup. • Boat overloaded or load improperly distributed. • Excessive water in bilge. • Boat bottom is dirty or damaged. Battery Will Not Hold Charge POSSIBLE CAUSES •...

  • Page 66: Owner Service Assistance

    Your satisfaction with your outboard product is very important to your dealer and to us. If you ever have a problem, question or concern about your outboard product, contact your dealer or any authorized Mercury Marine dealership. If additional assistance is required, take these steps.
  • Page 67 Telephone (954) 744-3500 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744-3535 U.S.A. Japan Telephone 81-053-423-2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81-053-423-2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way...

  • Page 68: Outboard Installation

    Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals...

  • Page 69: Fuel Tanks

    OUTBOARD INSTALLATION Fuel Tanks PORTABLE FUEL TANK Select a suitable location in the boat within the engine fuel line length limitations and secure the tank in place. PERMANENT FUEL TANK Permanent fuel tanks should be installed in accordance with industry and federal safety standards, which include recommendations applicable to grounding, anti-siphon protection, ventilation, etc.

  • Page 70: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION 20854 Lifting base Lifting eye Flywheel Puller/Lifting Ring 91-895343T02 Removes flywheel from engine. Used for lifting powerhead/engine. 14869 Steering Cable - Starboard Side Routed Cable Lubricate O-ring seal and entire cable end. 3724 Tube Ref No. Description Where Used Part No.

  • Page 71: Steering Link Rod Fasteners

    OUTBOARD INSTALLATION 3725 Torque nut to specification. 3727 Description lb. in. lb. ft. 47.5 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using special washer head bolt ("a" - Part Number 10-856680) and self-locking nylon insert locknuts ("c" & "d" - Part Number 11-826709113).
  • Page 72 OUTBOARD INSTALLATION 2897 Special washer head bolt (10-856680) Nylon insert locknut (11-826709113) Flat washers Nylon insert locknut (11-826709113) Description lb. in. lb. ft. Special washer head bolt Nylon insert locknut "d" Nylon insert locknut "c" Tighten until it seats, then back off 1/4 turn Assemble steering link rod to steering cable with two flat washers and nylon insert locknut.

  • Page 73: Determining Recommended Outboard Mounting Height

    OUTBOARD INSTALLATION Determining Recommended Outboard Mounting Height 63.5 cm (25 in.) 60.9 cm (24 in.) 58.4 cm (23 in.) 56.0 cm (22 in.) 53.3 cm (21 in.) 50.8 cm (20 in.) 48.2 cm (19 in.) 18562 The solid line is recommended to This line may be preferred to determine determine the outboard mounting height.

  • Page 74: Drilling Outboard Mounting Holes

    OUTBOARD INSTALLATION maximum speed is the only objective. 56.0 cm (22 in.), a propeller that is designed for surfacing operation is usually preferred. Maximum boat speed (MPH) anticipated NOTICE 1. The outboard should be mounted high enough on the transom so the exhaust relief hole will stay at least 25.4 mm (1 in.) above the waterline when the engine is running at idle speed.

  • Page 75: Fastening The Outboard To The Transom

    OUTBOARD INSTALLATION Transom Drilling Fixture 91-98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 Drill four 13.5 mm (17/32 in.) mounting holes. 3973 Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware - Supplied with Outboard Part Number Part Name Description...
  • Page 76 OUTBOARD INSTALLATION CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm (55 lb. ft.) of torque without the boat transom yielding or cracking. If the boat transom yields or cracks under this torque, the construction of the transom may not be adequate.

  • Page 77: Electrical, Fuel Hose, And Control Cables

    OUTBOARD INSTALLATION 3729 Flat washer (4) Locknut (4) 1/2 in. diameter bolt (4) Flat washer (4) Shank of bolt Description lb. in. lb. ft. Outboard mounting locknuts and bolts Electrical, Fuel Hose, and Control Cables FRONT COWL GROMMET Installation IMPORTANT: Sufficient slack must exist in wiring harnesses, battery cables, and hoses, that are routed between the rubber grommet and engine attachment points, to relieve stress and prevent hoses from being kinked or pinched.

  • Page 78: Remote Wiring Harness

    OUTBOARD INSTALLATION 20792 Access cover Battery cable opening Front grommet Speedometer tube opening Fuel hose opening SmartCraft harness or additional harness opening Remote wiring harness opening Shift cable opening Throttle cable opening Cable tie Route the hoses, wiring, and cables through the correct opening in the front grommet as shown. Reinstall the access cover with two bolts.
  • Page 79 OUTBOARD INSTALLATION 20791 14 pin connector Remote 14 pin boat harness SMARTCRAFT HARNESS CONNECTION If SmartCraft gauges are being used with the outboard, route the SmartCraft wiring harness through the front grommet and connect it to the SmartCraft harness connector on the engine. 20895 SmartCraft harness connector...
  • Page 80 OUTBOARD INSTALLATION BATTERY CABLE CONNECTIONS Single Outboard or86 Red sleeve - positive (+) Cranking battery Black sleeve - negative (–) Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. or87 Red sleeve - positive (+) Ground cable...

  • Page 81: Fuel Hose Connection

    OUTBOARD INSTALLATION FUEL HOSE CONNECTION Fasten remote fuel hose to fitting with hose clamp. Fuel Hose Size Minimum fuel hose inside diameter (ID) is 8 mm (5/16 in.) with separate fuel hose/fuel tank pickup for each engine. 20804 Hose clamp Fuel hose SHIFT CABLE INSTALLATION Install cables into the remote control following the instructions provided with the remote control.
  • Page 82 OUTBOARD INSTALLATION 20820 Locate the center point of the slack or lost motion that exists in the shift cable as follows: a. Move the remote control handle from neutral into forward and advance the handle to full speed position. Slowly return the handle back to the neutral position. Place a mark "a" on the cable against the cable end guide.
  • Page 83 OUTBOARD INSTALLATION 20824 Center mark Hairpin retainer Barrel insert Anchor pin Cable barrel Barrel holder Lock barrel in place with cable latch. 20825 Cable latch Check shift cable adjustments as follows: a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the cable end.

  • Page 84: Throttle Cable Installation

    OUTBOARD INSTALLATION 20905 Fuel hose retainer High pressure fuel hose THROTTLE CABLE INSTALLATION Install cables into the remote control following the instructions provided with the remote control. Remove the access cover from the bottom cowl. NOTE: The high pressure fuel hose can be moved out of the way for additional access. 20893 Access cover High pressure fuel hose...
  • Page 85 OUTBOARD INSTALLATION 20827 Throttle cable opening Retainer clip Flat washer Cable barrel Lock the cable in place with the cable latch. 20828 Cable latch If the shift cable is already installed, place the high pressure fuel hose back into the hose retainers. Reinstall the access cover.

  • Page 86: Trim In Pin

    OUTBOARD INSTALLATION 20905 Fuel hose retainer High pressure fuel hose Trim In Pin WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel.
  • Page 87 OUTBOARD INSTALLATION The owner may decide to limit the trim in. This can be accomplished by purchasing a stainless steel tilt pin from your dealer and insert it in whatever adjustment hole in the transom brackets is desired. A non-stainless steel shipping bolt should not be used in this application other than on a temporary basis.

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