Related Manuals for Mercury 200 EFI
Summarization of Contents
Notice
Notice to Users of This Manual
Outlines the manual's purpose, assumptions about the user's knowledge, and general safety advice.
Cleanliness and Care of Outboard Motor
Page Numbering
Explains how page numbers are formatted in the manual, using an example.
Service Manual Outline
Section 1 - General Information & Specifications
Covers general information and specifications for the engine.
Section 2 - Electrical
Details electrical systems, including ignition and charging.
Section 3 - Fuel System
Covers fuel pump, fuel injection, and oil injection systems.
Section 4 - Powerhead
Discusses the powerhead and cooling systems.
Section 5 - Mid-Section
Covers mid-section components like clamp/swivel brackets and power trim.
Section 6 - Gear Housing
Details gear housing specifications and components.
Section 7 - Attachments/Control Linkage
Covers steering cables, link rods, and related components.
Section 8 - Color Diagrams
Provides color diagrams for the wiring and systems.
IMPORTANT INFORMATION
Section 1A - Specifications
Provides detailed specifications for the engine models.
SPECIFICATIONS
MID SECTION
Specifications for power trim, tilt pin, steering pivot range, and transom thickness.
FUEL SYSTEM
Fuel type, recommended gasoline, recommended oil, and gasoline/oil ratio.
STARTING SYSTEM
Specifications for electric start, starter draw, brush length, and battery rating.
IGNITION SYSTEM
Spark plug type, gap, firing order, timing, and throttle position sensor.
CHARGING SYSTEM
Alternator output, brush length, voltage output, and regulator current draw.
SPECIFICATIONS
GEAR HOUSING
Gear ratios, gearcase capacity, pinion height, and backlash.
OIL INJECTION
Recommended oil, oil tank capacity, and oil pump output.
FUEL INJECTION
Idle RPM, WOT RPM, float adjustment, injectors, line pressure, and resistance.
SPECIFICATIONS
Mercury/Quicksilver Lubricants and Sealants
Table of Mercury/Quicksilver part numbers for lubricants and sealants.
SPECIFICATIONS
Mercury/Quicksilver Lubricants and Sealants (continued)
Continues the table of Mercury/Quicksilver part numbers for lubricants and sealants.
IMPORTANT INFORMATION
Section 1B - Maintenance
Covers inspection and maintenance schedules and procedures.
MAINTENANCE
Special Tools
Lists and illustrates special tools required for maintenance.
Mercury/Quicksilver Lubricants and Sealants
Refers to Section 1A for the lubricants and sealants chart.
MAINTENANCE
Inspection and Maintenance Schedule
Details maintenance tasks based on usage intervals (before use, after use, every 100 hours/yearly).
MAINTENANCE
Flushing Engine
Provides instructions for flushing the cooling system using cowl flush plug or attachment.
MAINTENANCE
Fuel System
Covers fuel line inspection and water separating fuel filter (EFI models).
MAINTENANCE
Corrosion Control Anode
Discusses inspection and replacement of corrosion control anodes.
Spark Plug Inspection and Replacement
Details how to inspect, clean, and replace spark plugs.
MAINTENANCE
Battery Inspection
Outlines how to inspect the battery for proper engine starting capability.
Fuse Replacement
Explains how to identify and replace blown fuses.
MAINTENANCE
Lubrication Points
Identifies and describes lubrication points for various components.
MAINTENANCE
Checking Power Trim Fluid
Details how to check and add power trim fluid.
MAINTENANCE
Gear Case Lubrication
Instructions for draining, checking, and refilling gear case lubricant.
MAINTENANCE
Storage Preparation
Procedures for preparing the outboard for storage to protect against damage.
MAINTENANCE
POSITIONING OUTBOARD FOR STORAGE
Recommends storing the outboard in an upright position for water drainage.
BATTERY STORAGE
Provides instructions for proper battery storage.
IMPORTANT INFORMATION
Section 1C - General Information
Provides general information about the engine, including serial number location.
GENERAL INFORMATION
Conditions Affecting Performance
Discusses how weather conditions affect engine power output and performance.
GENERAL INFORMATION
Trim
Details trimming outboard "IN" characteristics and discusses water absorption, cavitation, and ventilation.
GENERAL INFORMATION
Engine
Discusses engine detonation causes and prevention, and engine compression checks.
GENERAL INFORMATION
Following Complete Submersion
Instructions for handling engines submerged in salt or fresh water.
GENERAL INFORMATION
Following Complete Submersion (continued)
Continues instructions for handling submerged engines, including starter motor and oil injection systems.
GENERAL INFORMATION
Model 150 XRI/175 XRI/200 XRI Powerhead Front View
Labeled diagram of the powerhead front view with component identification.
GENERAL INFORMATION
Model 150 XRI/175 XRI/200 XRI Powerhead Starboard View
Labeled diagram of the powerhead starboard view with component identification.
GENERAL INFORMATION
Model 150 XRI/175 XRI/200 XRI Powerhead Port View
Labeled diagram of the powerhead port view with component identification.
GENERAL INFORMATION
Model 150 XRI/175 XRI/200 XRI Powerhead Top View
Labeled diagram of the powerhead top view with component identification.
GENERAL INFORMATION
Model 150 XRI/175 XRI/200 XRI Powerhead Aft View
Labeled diagram of the powerhead aft view with component identification.
GENERAL INFORMATION
Painting Procedures
Instructions for cleaning and painting top cowls.
Cleaning & Painting Aluminum Propellers & Gear Housings
Procedures for cleaning and painting propellers and gear housings.
GENERAL INFORMATION
GEAR HOUSINGS
Procedures for refinishing gear housings.
GENERAL INFORMATION
Decal Application
Instructions for decal removal and application, including tools and surface preparation.
GENERAL INFORMATION
Decal Application (continued)
Details the wet application method for decals, including steps for positioning and smoothing.
IMPORTANT INFORMATION
Section 1D - Outboard Motor Installation
Covers the installation of the outboard motor, including specifications and lifting procedures.
OUTBOARD MOTOR INSTALLATION
Installing Outboard to Boat Transom
Details determining the recommended outboard mounting height and mounting procedures.
OUTBOARD MOTOR INSTALLATION
Installing Outboard (continued)
Instructions for drilling outboard mounting holes.
OUTBOARD MOTOR INSTALLATION
Securing Outboard To Boat Transom
Details securing the outboard to the boat transom with provided hardware.
Steering Cable
Instructions for lubricating the starboard side routed steering cable.
OUTBOARD MOTOR INSTALLATION
Steering Cable (continued)
Details inserting the steering cable into the tilt tube and torquing the nut.
Steering Link Rod
Instructions for installing the steering link rod and associated hardware.
OUTBOARD MOTOR INSTALLATION
Electrical, Hoses and Control Cables
Covers warning horn requirements and notes on opening the front clamp assembly.
Remote Wiring Harness
Instructions for connecting the remote wiring harness.
OUTBOARD MOTOR INSTALLATION
Battery Cables
Shows battery cable connections for single and dual outboard installations.
OUTBOARD MOTOR INSTALLATION
Fuel Hose Connection
Specifies fuel hose size and fastening.
Oil Hose Connections
Details connecting remote oil hoses to engine connections.
Speedometer Tubing Connection
Instructions for connecting water tubing for the speedometer.
Water Pressure Tubing Connection
Details making water connections for a water pressure gauge.
OUTBOARD MOTOR INSTALLATION
Shift Cable
Instructions for installing shift cables into the remote control.
COUNTER ROTATION OUTBOARDS
Identifies counter-rotating gear cases and specifies required controls.
OUTBOARD SHIFTING DIRECTION
Explains shift linkage direction for counter-rotation outboards compared to standard.
OUTBOARD MOTOR INSTALLATION
Installation
Details proper adjustment of the shift cable using reference marks.
OUTBOARD MOTOR INSTALLATION
Installation (continued)
Describes checking and adjusting shift cable connections for proper gear engagement.
OUTBOARD MOTOR INSTALLATION
Throttle Cable
Instructions for installing and adjusting the throttle cable.
OUTBOARD MOTOR INSTALLATION
Front Clamp Reassembly
Instructions for reassembling the front clamp, emphasizing harness and cable slack.
OUTBOARD MOTOR INSTALLATION
Oil Injection Set-Up
Cautionary notes regarding contamination and installation of remote oil tank.
OUTBOARD MOTOR INSTALLATION
Installing Oil Hoses To Engine
Details routing and connecting oil hoses, including directional filters and vents.
OUTBOARD MOTOR INSTALLATION
Filling
Instructions for filling the remote oil tank and engine oil reservoir with recommended oil.
OUTBOARD MOTOR INSTALLATION
Priming the Oil Pump
Explains the importance of priming the oil pump and lists three methods.
OUTBOARD MOTOR INSTALLATION
Priming Procedure – Method 1
Details the shift switch activation prime procedure, outlining its three key functions.
OUTBOARD MOTOR INSTALLATION
Purging Air From the Engine Oil Reservoir
Instructions for purging air from the engine oil reservoir.
Trim In Stop Adjustment
Discusses adjusting trim "in" stop for improved boat attitude and handling.
OUTBOARD MOTOR INSTALLATION
Trim Tab Adjustment
Explains how to adjust trim tabs to compensate for steering torque and improve boat handling.
ELECTRICAL
Section 2A - Ignition
Covers ignition system specifications, tests, and component descriptions.
IGNITION
Specifications
Provides specifications for the ignition system, including spark plug type and gap.
Ignition Coil Ohms Test
Details the procedure for testing ignition coil resistance using a multimeter.
IGNITION
Manifold Absolute Pressure (MAP) Sensor Ohms Test
Provides instructions for testing the MAP sensor's resistance.
Crank Position Sensor Resistance Test
Specifies resistance values for the crank position sensor.
Throttle Position Sensor Specifications
Lists voltage specifications for the throttle position sensor at idle and wide open throttle.
IGNITION
Port and Starboard Temperature Sensors; Air Temperature Sensor
Details ohm testing procedures for temperature sensors and provides specifications.
IGNITION
Special Tools
Lists and illustrates special tools required for ignition system testing and troubleshooting.
IGNITION
Special Tools (continued)
Continues the list of special tools, including timing lights and crankshaft protectors.
IGNITION
Special Tools (continued)
Lists flywheel puller, holder, and heat lamp as special tools.
IGNITION
Coil Plate Assembly
Labeled diagram of the coil plate assembly with numbered components.
IGNITION
Coil Plate Assembly (continued)
Provides a table of torque specifications for the coil plate assembly components.
IGNITION
Electrical Plate Assembly
Diagram of the electrical plate assembly with numbered components.
IGNITION
Electrical Plate Assembly (continued)
Provides a table of torque specifications for the electrical plate assembly components.
IGNITION
Theory of Operation
Explains the operation of the ignition system, including ECM, relays, and coil functions.
IGNITION
Ignition Component Description
Describes fuses and identifies circuits protected by them.
IGNITION
Charging System Alternator
Explains the function of the belt-driven alternator and battery charging system.
Ignition Coil
Describes the function of ignition coil modules in producing high voltage.
IGNITION
Electronic Control Module
Explains the ECM's functions, including calculating fuel/ignition timing and controlling injectors.
IGNITION
Flywheel
Describes the flywheel's role in providing engine RPM and crankshaft position information to the ECM.
Crank Position Sensor
Explains the function of the crank position sensor in determining crankshaft position and engine speed.
IGNITION
Throttle Position Sensor (TPS)
Explains the TPS function, how voltage changes, and troubleshooting steps.
IGNITION
Cylinder Head Temperature Sensor
Describes the function of cylinder head temperature sensors in providing ECM signals for fuel enrichment and timing.
Air Temperature Sensor
Explains how the air temperature sensor transmits manifold air temperature to the ECM to regulate fuel flow.
IGNITION
Port and Starboard Temperature Sensors; Air Temperature Sensor
Details ohm testing procedures for temperature sensors and provides specifications.
IGNITION
Manifold Absolute Pressure (MAP) Sensor
Explains the MAP sensor's function in regulating fuel flow and how to test its operation using DDT.
IGNITION
Ignition Troubleshooting and Fault Chart
Provides a chart for diagnosing ignition system problems and their corresponding actions.
IGNITION
Ignition Troubleshooting and Fault Chart (continued)
Continues the fault chart for ignition system issues, covering engine cranking and stalling.
IGNITION
Ignition Troubleshooting and Fault Chart (continued)
Continues the fault chart, addressing engine idle issues, rough running, and speed reduction.
IGNITION
Ignition Troubleshooting and Fault Chart (continued)
Continues the fault chart, covering speed reduction and loss of spark on cylinders.
IGNITION
Ignition Coil Ohms Test
Details the procedure for testing ignition coil resistance using a multimeter.
IGNITION
Manifold Absolute Pressure (MAP) Sensor Ohms Test
Provides instructions for testing the MAP sensor's resistance.
Idle Speed Control
Explains how the ECM controls idle speed by adjusting timing and fuel flow.
RPM-Limit Circuit
Describes the RPM limit circuitry within the ECM and its functions.
IGNITION
EFI Detonation Control System (200 Model only)
Explains the detonation control circuit, its sensors, and how timing is retarded.
Detonation Circuit Test
Details testing the detonation circuit using the Digital Diagnostic Terminal.
IGNITION
Troubleshooting
Provides general troubleshooting advice for the ECM and its sensors.
Troubleshooting Without Digital Diagnostic Terminal
Outlines troubleshooting steps without using the DDT, focusing on resistance checks.
IGNITION
Troubleshooting with the Digital Diagnostic Terminal
Explains how to use the Quicksilver Digital Diagnostic Terminal (DDT) for diagnosis.
IGNITION
DDT Functions – EFI Models
Lists DDT functions and describes how to select functions and view fault history.
IGNITION
Ignition Component Removal and Installation
Provides instructions for removing the flywheel, including necessary tools and precautions.
IGNITION
Flywheel Installation
Details the process of reinstalling the flywheel, including cleaning and torquing procedures.
Ignition Coil Removal
Outlines steps for removing the ignition coil, including safety warnings.
IGNITION
Ignition Coil Installation
Instructions for securing the ignition coil, reconnecting harness, and spark plug lead.
Electronic Control Module Removal
Steps for removing the electronic control module by disconnecting harness and bolts.
Electronic Control Module Installation
Instructions for installing the electronic control module, including torquing bolts.
IGNITION
Temperature Sensor Removal
Instructions for removing analog and digital temperature sensors.
Engine Head Temperature Sensor Installation
Details installation of analog and digital temperature sensors, including torquing.
IGNITION
Air Temperature Sensor Removal
Instructions for disconnecting the sensor harness and unscrewing the sensor.
Air Temperature Sensor Installation
Details installing the air temperature sensor and reconnecting the harness.
Manifold Absolute Pressure (MAP) Sensor Removal
Instructions for disconnecting the MAP sensor harness and removing the sensor.
Manifold Absolute Pressure (MAP) Sensor Installation
Details securing and reconnecting the MAP sensor.
IGNITION
Crank Position Sensor Removal
Instructions for disconnecting the sensor harness and removing securing screws.
Crank Position Sensor Installation
Details securing the crank position sensor and reconnecting the harness.
ELECTRICAL
Section 2B – Charging & Starting System
Covers specifications, special tools, battery, and charging/starting system components.
ELECTRICAL
Specifications
Provides specifications for charging and starting systems, including alternator output and battery rating.
ELECTRICAL
Special Tools
Lists and illustrates special tools for charging and starting system work.
ELECTRICAL
Battery Cable Size
Provides a chart for selecting the correct wire gauge size for battery cables based on length.
Replacement Parts
Warns about using non-compliant replacement parts and potential hazards.
Recommended Battery
Recommends a 12-volt marine battery with specific cranking amperage ratings.
ELECTRICAL
Battery
Provides precautions for handling batteries, including warnings about explosive gas.
Charging a Discharged Battery
Outlines the basic rule for battery charging, including safe rates and temperature limits.
ELECTRICAL
Winter Storage of Batteries
Provides instructions for safely storing batteries during winter to prevent damage.
ELECTRICAL
Flywheel Removal and Installation
Details the process for removing the flywheel, including necessary tools and precautions.
ELECTRICAL
Flywheel Installation
Instructions for reinstalling the flywheel, emphasizing cleaning and dry assembly.
ELECTRICAL
Notes:
Blank page for notes.
ELECTRICAL
Flywheel/Alternator
Exploded view diagram of the flywheel and alternator components.
ELECTRICAL
Flywheel/Alternator (continued)
Provides a table of torque specifications for flywheel and alternator components.
ELECTRICAL
System Components
Identifies the components of the battery charging system and their connections.
Precautions
Lists precautions to observe when working on the alternator system to prevent damage.
ELECTRICAL
Alternator Description
Describes the alternator's construction, operation, and voltage regulation.
Diagnosis of Alternator System on Engine
Provides steps for diagnosing alternator system problems on the engine.
ELECTRICAL
Alternator System Circuitry Test
Details tests for the alternator system's output circuit using a voltmeter.
ELECTRICAL
Alternator System Circuitry Test (continued)
Details tests for the alternator system's sensing circuit using a voltmeter.
ELECTRICAL
Voltage Output
Explains how to check the alternator's voltage output and what normal values are.
ELECTRICAL
Current Output
Details how to test alternator current output, including a table of expected values.
ELECTRICAL
Current Output Troubleshooting
Lists possible causes and actions for low or high current output issues.
Repair
Outlines the removal steps for the alternator.
ELECTRICAL
Installation
Details the installation of the alternator, including torquing and belt alignment.
ELECTRICAL
Alternator Belt Tension Adjustment
Explains how to adjust alternator belt tension using a tensioner assembly.
ELECTRICAL
Starter System
Introduces the starter system components and describes its purpose.
Starter Motor Amperes Draw
Lists starter draw and brush length specifications for different starter types.
Starter System Components
Lists components of the starter system.
Description
Explains the purpose of the starter motor and its circuit activation.
ELECTRICAL
Starter Motor (Centrifugal Bendix)
Exploded view diagram of the starter motor with centrifugal bendix.
ELECTRICAL
Starter Motor (Centrifugal Bendix) (continued)
Provides a table of torque specifications for the centrifugal bendix starter motor components.
ELECTRICAL
Troubleshooting the Starter Circuit (Centrifugal Bendix)
Verifies conditions before beginning troubleshooting, lists test points.
ELECTRICAL
Starter Circuit Troubleshooting Flow Chart (Centrifugal Bendix)
Flow chart to diagnose starter motor not turning issues.
ELECTRICAL
Starter Circuit Troubleshooting Flow Chart (Centrifugal Bendix) (continued)
Continues the flow chart for diagnosing starter motor not turning issues.
ELECTRICAL
Starter Removal (Centrifugal Bendix)
Instructions for disconnecting battery leads, starter wires, and removing starter.
Starter Installation (Centrifugal Bendix)
Details installing the starter, including rubber collars, spacers, and torque specifications.
ELECTRICAL
Starter Disassembly (Centrifugal Bendix)
Instructions for disassembling the starter motor, including removing through bolts and brush springs.
ELECTRICAL
Starter Disassembly (Centrifugal Bendix) (continued)
Continues starter disassembly, including removing armature, drive assembly, and other parts.
ELECTRICAL
Starter Cleaning, Inspection and Testing
Guides on cleaning and inspecting starter motor parts, including commutator resurfacing.
ELECTRICAL
TESTING
Describes armature tests for shorts and grounds using a growler and ohmmeter.
ELECTRICAL
Checking Positive Brushes and Terminal
Details checking positive brushes and terminals with an ohmmeter for continuity.
Testing Negative Brushes for Ground
Explains how to test negative brushes for ground using an ohmmeter.
ELECTRICAL
Starter Reassembly
Instructions for installing positive brushes, terminals, and end caps.
ELECTRICAL
Starter Reassembly (continued)
Details installing negative brushes, brush holders, and reassembling parts onto the armature shaft.
ELECTRICAL
Starter Reassembly (continued)
Describes installing the field frame, brush plate, and end plate, including torque specifications.
ELECTRICAL
Ignition Coil Installation
Instructions for securing the ignition coil, reconnecting harness, and spark plug lead.
Electronic Control Module Removal
Steps for removing the electronic control module by disconnecting harness and bolts.
Electronic Control Module Installation
Instructions for installing the electronic control module, including torquing bolts.
IGNITION
Temperature Sensor Removal
Instructions for removing analog and digital temperature sensors.
Engine Head Temperature Sensor Installation
Details installation of analog and digital temperature sensors, including torquing.
IGNITION
Air Temperature Sensor Removal
Instructions for disconnecting the sensor harness and unscrewing the sensor.
Air Temperature Sensor Installation
Details installing the air temperature sensor and reconnecting the harness.
Manifold Absolute Pressure (MAP) Sensor Removal
Instructions for disconnecting the MAP sensor harness and removing the sensor.
Manifold Absolute Pressure (MAP) Sensor Installation
Details securing and reconnecting the MAP sensor.
IGNITION
Crank Position Sensor Removal
Instructions for disconnecting the sensor harness and removing securing screws.
Crank Position Sensor Installation
Details securing the crank position sensor and reconnecting the harness.
IGNITION
Throttle Position Sensor (TPS)
Explains the TPS function, how voltage changes, and troubleshooting steps.
IGNITION
Throttle Position Sensor (TPS) Troubleshooting
Provides troubleshooting steps for TPS failure, including checking cable adjustment and roller/cam alignment.
IGNITION
Cylinder Head Temperature Sensor
Describes the function of cylinder head temperature sensors in providing ECM signals for fuel enrichment and timing.
Air Temperature Sensor
Explains how the air temperature sensor transmits manifold air temperature to the ECM to regulate fuel flow.
IGNITION
Port and Starboard Temperature Sensors; Air Temperature Sensor
Details ohm testing procedures for temperature sensors and provides specifications.
IGNITION
Manifold Absolute Pressure (MAP) Sensor
Explains the MAP sensor's function in regulating fuel flow and how to test its operation using DDT.
IGNITION
Ignition Troubleshooting and Fault Chart
Provides a chart for diagnosing ignition system problems and their corresponding actions.
IGNITION
Ignition Troubleshooting and Fault Chart (continued)
Continues the fault chart for ignition system issues, covering engine cranking and stalling.
IGNITION
Ignition Troubleshooting and Fault Chart (continued)
Continues the fault chart, addressing engine idle issues, rough running, and speed reduction.
IGNITION
Ignition Troubleshooting and Fault Chart (continued)
Continues the fault chart, covering speed reduction and loss of spark on cylinders.
IGNITION
Ignition Coil Ohms Test
Details the procedure for testing ignition coil resistance using a multimeter.
IGNITION
Manifold Absolute Pressure (MAP) Sensor Ohms Test
Provides instructions for testing the MAP sensor's resistance.
Idle Speed Control
Explains how the ECM controls idle speed by adjusting timing and fuel flow.
RPM-Limit Circuit
Describes the RPM limit circuitry within the ECM and its functions.
IGNITION
EFI Detonation Control System (200 Model only)
Explains the detonation control circuit, its sensors, and how timing is retarded.
Detonation Circuit Test
Details testing the detonation circuit using the Digital Diagnostic Terminal.
IGNITION
Troubleshooting
Provides general troubleshooting advice for the ECM and its sensors.
Troubleshooting Without Digital Diagnostic Terminal
Outlines troubleshooting steps without using the DDT, focusing on resistance checks.
IGNITION
Troubleshooting with the Digital Diagnostic Terminal
Explains how to use the Quicksilver Digital Diagnostic Terminal (DDT) for diagnosis.
ELECTRICAL
Section 2C - Timing, Synchronizing & Adjusting
Covers timing specifications, special tools, and adjustments.
ELECTRICAL
Special Tools
Lists and illustrates special tools for timing, synchronizing, and adjusting.
ELECTRICAL
Adjustments
Provides important notes on factory settings and procedures for resetting throttle linkage.
Throttle Cam Adjustment
Details how to loosen cam follower screw, align roller on throttle cam, and adjust clearance.
ELECTRICAL
Timing
Explains that ECM controls timing and lists idle and 5000 RPM timing specifications.
Maximum Throttle Adjustment
Instructions for adjusting the full throttle stop screw to achieve proper throttle valve opening.
ELECTRICAL
Throttle Position Sensor
Explains TPS function, monitoring with DDT, and voltage specifications.
Idle Speed
Notes that idle speed is ECM controlled and not adjustable.
Throttle Cable Installation
Details connecting throttle cable, adjusting barrel for preload, and checking for excessive preload.
ELECTRICAL
Throttle Plate Screw
Important note about not adjusting the factory throttle plate stop screw, but how to adjust clearance if needed.
ELECTRICAL
Section 2D – Wiring Diagrams
Lists various wiring diagrams for different systems and components.
ELECTRICAL
Power Trim Wiring Diagram
Shows the wiring connections for the power trim system, including components and color codes.
ELECTRICAL
Instrument Wiring Connections
Illustrates instrument wiring connections, including wire colors and destinations.
ELECTRICAL
Commander 3000 Classic Panel Remote Control
Wiring diagram for the Commander 3000 Classic panel remote control.
ELECTRICAL
Commander 3000 Panel Remote Control
Wiring diagram for the Commander 3000 panel remote control.
ELECTRICAL
4000 Series Mechanical Panel Control
Wiring diagram for the 4000 Series mechanical panel control.
ELECTRICAL
Instrument/Lanyard Stop Switch Wiring Diagram
Wiring diagram for the instrument and lanyard stop switch.
ELECTRICAL
Oil Level Gauge Wiring Diagram
Wiring diagram for the oil level gauge.
ELECTRICAL
Notes:
Blank page for notes.
ELECTRICAL
Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
Wiring diagram for instrument/lanyard stop switch on dual outboard installations.
ELECTRICAL
Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard) (continued)
Continues wiring diagram for dual outboard installations, showing starboard connections.
ELECTRICAL
QSI Gauge Wiring Diagrams
Wiring diagrams for QSI gauges, specifically the tachometer.
ELECTRICAL
Water Temperature Gauge
Wiring diagrams for water temperature gauge, showing connections for separate light switch or direct ignition key switch.
ELECTRICAL
Oil Level Gauge Wiring
Wiring diagram for oil level gauge, showing light bulb positions and sender wiring.
ELECTRICAL
Oil Level Gauge Wiring (continued)
Shows wiring for light bulb positions B and sender wiring for the oil level gauge.
ELECTRICAL
Engine Synchronizer Wiring Diagram
Wiring diagrams for synchronizer, showing gauge needle position relative to engine speed.
ELECTRICAL
Synchronizer wiring can be accomplished two different ways as an option to the user.
Wiring diagrams illustrating two methods for synchronizer wiring: slow and fast running engine.
Maintenance
Basic cleaning instructions for gauges.
ELECTRICAL
Warning System Signals
Table detailing warning system signals for various problems, including horn, display, Guardian activation, and engine speed reduction.
ELECTRICAL
Guardian Protection System
Explains how the guardian protection system monitors critical engine functions and reduces power.
Guardian System Operation with Gauges
Describes how the system sounds a warning horn and displays messages.
Guardian System Activation
Details Guardian System activation for cooling system problems, oil level, and oil pump failure.
ELECTRICAL
Guardian Protection System (continued)
Describes Guardian System activation for engine overspeed and sensor out-of-range conditions.
ELECTRICAL
Analog Gauge Panel Mount Remote Control Wiring Installation
Wiring diagram for analog gauge panel mount remote control installation.
ELECTRICAL
System Monitor V2.0
Introduces the System Monitor as an LCD multi-function display gauge.
Basic Operation
Explains basic operation, button functions, lighting, troll control, and warning systems.
Initial Power Up (Or After Master Reset)
Details the initial power-up sequence and auto-detection of engine type.
ELECTRICAL
Standard Information Display Screens
Describes startup screen, RPM screen, and fuel used screen.
Standard Information Display Screens (continued)
Provides notes on screen applicability and calibration options.
ELECTRICAL
FUEL FLOW SCREEN
Describes the fuel flow screen, showing estimated fuel consumption per hour.
TRIM POSITION SCREEN
Explains the trim position screen and its display of trim and trailer positions.
ENGINE TEMPERATURE SCREEN
Describes the engine temperature screen, showing Fahrenheit or Celsius readings.
WATER PRESSURE SCREEN
Explains the water pressure screen, showing cooling system water pressure.
OIL TEMPERATURE SCREEN
Describes the oil temperature screen, showing Fahrenheit or Celsius readings.
ELECTRICAL
OIL PRESSURE SCREEN
Explains the oil pressure screen, showing pressure in Psi or Bar.
BATTERY VOLTAGE SCREEN
Describes the battery voltage screen, showing voltage level and condition.
Display of Range and Depth Information
Covers range screen (estimated traveling range) and water depth screen.
ELECTRICAL
SHALLOW WATER ALARM FEATURE
Explains how to set a shallow water alarm to trigger when the boat enters shallower water.
Warning System
Describes the warning system, incorporating display screens, horn, and Guardian Protection.
ELECTRICAL
Warning Display Screens
Explains the "Engine Guardian System" and how it monitors critical functions to reduce engine power.
ALARM – OVERHEAT
Describes the overheat alarm, its icons, horn sound, and engine power limiting.
ALARM – LOW WATER PRESSURE
Details the low water pressure alarm, its icons, horn sound, and potential causes.
ELECTRICAL
ALARM – LOW OIL RESERVE – OUTBOARD 2 STROKE ONLY
Explains the low oil reserve alarm and its actions.
ALARM – OIL PUMP FAULT
Describes the oil pump fault alarm, horn sound, and engine power limiting.
ALARM – ENGINE OVERSPEED
Explains the engine overspeed alarm and how the system automatically reduces engine speed.
ELECTRICAL
ALARM – WATER IN FUEL
Details the water in fuel alarm, horn sound, and filter removal reference.
ALARM – LOW FUEL
Explains the low fuel alarm, horn sound, and conditions for reoccurrence.
ALARM – ENGINE MALFUNCTION
Describes the engine malfunction alarm and Engine Guardian System response.
INSTALLATION ERROR DETECTION
Explains messages displayed by the System Monitor during installation errors.
ELECTRICAL
CAL1 Calibration
Outlines Cal1 display calibrations and procedures for header screen and trim pop-up screen.
ELECTRICAL
CAL1 Calibration (continued)
Details calibration steps for English/Metric unit selection, range readings, and data page selections.
ELECTRICAL
CAL2 Calibration
Outlines Cal2 display calibrations and procedures for pitot sensor settings and multipliers.
ELECTRICAL
CAL2 Calibration (continued)
Details fuel tank calibration procedures, including different methods and filling steps.
ELECTRICAL
CAL2 Calibration (continued)
Continues fuel tank calibration steps for 0%, 25%, 50%, 75%, and FULL capacity.
ELECTRICAL
CAL2 Calibration (continued)
Details tank 2 calibration and the Master Reset Command procedure.
ELECTRICAL
System Tach & Speed
Describes basic operation and features of the tachometer and speedometer gauges.
Basic Operation and Features
Explains power up, button functions, lighting, troll control, and warning systems.
Gauge Calibrations
Lists the digital display screens available for engine information.
ELECTRICAL
Speedometer Display Screens
Describes various speedometer display screens, including clock, fuel level, oil level, and RPM synchronizer.
ELECTRICAL
Tachometer Display Screens
Describes various tachometer display screens, including engine break-in, temperature, and power trim angle.
ELECTRICAL
Troll Control
Explains basic operation of troll control for maintaining trolling speeds without throttle.
TO SET TROLL CONTROL
Steps for setting troll control speed using tachometer or speedometer.
ELECTRICAL
EXITING TROLL CONTROL
Describes three ways to turn off the troll control.
Warning System
Explains how the SmartCraft warning system incorporates display screens, horn, and Guardian Protection.
ELECTRICAL
Alarm Messages
Lists alarm messages and indicates which display and system activations occur.
ELECTRICAL
OVERSPEED (a)
Explains the overspeed alarm and how the system automatically reduces engine speed.
WATER IN FUEL (b)
Details the water in fuel alarm, horn sound, and filter removal reference.
FAULT-HORN (c)
Explains the fault horn alarm, indicating a malfunction in the horn system.
RESERVE OIL LOW – 2 STROKE OUTBOARD ONLY (d)
Describes the low oil reserve alarm and its actions.
FAULT-OIL PUMP (e)
Explains the oil pump fault alarm, horn sound, and engine power limiting.
FAULT-INJECTOR (f)
Indicates if one or more fuel injectors have stopped functioning electrically.
FAULT-IGNITION (g)
Informs about a problem in the ignition system.
ELECTRICAL
BATTERY (a)
Explains the battery warning message and Engine Guardian System actions for low battery charge.
ENGINE DATA BUS (b)
Indicates a problem with the data communication link between the tachometer and engine.
UNIT MISMATCH (c)
Informs about tachometers not being calibrated alike, possibly due to English/Metric settings.
LOW FUEL LEVEL (d)
Warns about critically low fuel level in the tank, advising to stop for fuel.
LOW OIL LEVEL – OUTBOARD 2 STROKE ONLY (e)
Warns about low oil level in the remote oil tank, advising to stop and refill.
FAULT-SENSOR (f)
Informs if a sensor is not functioning correctly, detailing effects of throttle or temperature sensor failure.
ELECTRICAL
WARNING NO STARBOARD ENGINE (a)
Informs that the instrument does not see the starboard engine computer, usually due to wiring issues.
WARNING MULTIPLE STARBOARD ENGINE (b)
Informs that instruments recognize multiple engines as starboard, requiring configuration.
OIL TEMPERATURE (c)
Describes the oil temperature alarm and Engine Guardian System action.
OIL PRESSURE (d)
Details the oil pressure alarm and its cause (insufficient oil pressure).
Auto-Detection Engine Function
Explains how the system auto-detects engine type for gauge preconfiguration.
Master Reset Command
Describes how to return the gauge to factory presets via the Master Reset command.
ELECTRICAL
Tachometer Calibration
Outlines Quick Cal and Cal1 calibration procedures for lighting, contrast, and screen configuration.
ELECTRICAL
CALIBRATION
Details calibration steps for trim, display units, speed units, and sensor inputs.
ELECTRICAL
CALIBRATION (continued)
Continues calibration steps for trim, display units, speed units, and sensor inputs.
ELECTRICAL
CAL2 Calibration
Outlines Cal2 display calibrations and procedures for pitot sensor settings and multipliers.
ELECTRICAL
CAL2 Calibration (continued)
Details fuel tank calibration procedures, including different methods and filling steps.
ELECTRICAL
CALIBRATION
Details calibration steps for speed units, external sensors, and simulator mode.
ELECTRICAL
AIR TEMP?
Asks if an air temp sensor is being used.
GPS?
Asks if a GPS sensor is installed.
USE GPS SPEED?
Asks if GPS input should be used to drive the speed display.
WATER TEMPERATURE ADJUST
Adjusts water temp. transducer to match actual sea water temperature.
ELECTRICAL
SmartCraft Gauge Operation
Describes basic operation and features of SmartCraft gauges.
ELECTRICAL
Basic Operation and Features
Explains power up, button functions, lighting, troll control, and warning systems.
ELECTRICAL
Troll Control
Explains basic operation of troll control for maintaining trolling speeds without throttle.
TO SET TROLL CONTROL
Steps for setting troll control speed using tachometer or speedometer.
ELECTRICAL
EXITING TROLL CONTROL
Describes three ways to turn off the troll control.
Warning System
Explains how the SmartCraft warning system incorporates display screens, horn, and Guardian Protection.
ELECTRICAL
Alarm Messages
Lists alarm messages and indicates which display and system activations occur.
ELECTRICAL
OVERHEAT
Describes the overheat alarm, its icons, horn sound, and engine power limiting.
PRESSURE
Details the pressure alarm, its icons, horn sound, and potential causes.
OVERSPEED (a)
Explains the overspeed alarm and how the system automatically reduces engine speed.
WATER IN FUEL (b)
Details the water in fuel alarm, horn sound, and filter removal reference.
FAULT-HORN (c)
Explains the fault horn alarm, indicating a malfunction in the horn system.
RESERVE OIL LOW – 2 STROKE OUTBOARD ONLY (d)
Describes the low oil reserve alarm and its actions.
FAULT-OIL PUMP (e)
Explains the oil pump fault alarm, horn sound, and engine power limiting.
FAULT-INJECTOR (f)
Indicates if one or more fuel injectors have stopped functioning electrically.
FAULT-IGNITION (g)
Informs about a problem in the ignition system.
ELECTRICAL
BATTERY (a)
Explains the battery warning message and Engine Guardian System actions for low battery charge.
ENGINE DATA BUS (b)
Indicates a problem with the data communication link between the tachometer and engine.
UNIT MISMATCH (c)
Informs about tachometers not being calibrated alike, possibly due to English/Metric settings.
LOW FUEL LEVEL (d)
Warns about critically low fuel level in the tank, advising to stop for fuel.
LOW OIL LEVEL – OUTBOARD 2 STROKE ONLY (e)
Warns about low oil level in the remote oil tank, advising to stop and refill.
FAULT-SENSOR (f)
Informs if a sensor is not functioning correctly, detailing effects of throttle or temperature sensor failure.
ELECTRICAL
FAULT-WATER TEMP (f)
Informs that the sensor for measuring outside lake/sea water temperature is not functioning.
ELECTRICAL
Tachometer Calibration
Outlines Quick Cal and Cal1 calibration procedures for lighting, contrast, and screen configuration.
ELECTRICAL
CALIBRATION
Details calibration steps for speed units, external sensors, and simulator mode.
ELECTRICAL
CAL2 Calibration
Outlines Cal2 display calibrations and procedures for pitot sensor settings and multipliers.
ELECTRICAL
CAL2 Calibration (continued)
Details fuel tank calibration procedures, including different methods and filling steps.
ELECTRICAL
CALIBRATION
Details calibration steps for time, external sensors, and simulator mode.
ELECTRICAL
SmartCraft Gauge Test Specifications
Provides test equipment required and specifications for SmartCraft gauges.
WIRING DIAGRAMS
150/175/200 EFI Wiring Diagram
Shows the complete wiring diagram for the 150/175/200 EFI models.
COLOR DIAGRAMS
Table of Contents
Lists the color diagrams available in the manual.
COLOR DIAGRAMS
Notes:
Blank page for notes.
COLOR DIAGRAMS
150/175/200 EFI WIRING DIAGRAM 2002 MODEL YEAR
Title page for the wiring diagram.
COLOR DIAGRAMS
TYPICAL SMARTCRAFT SYSTEM TACHOMETER & SYSTEM SPEEDOMETER INSTALLATION WITH SYSTEM LINK GAUGES 2002 MODEL YEAR
Title page for the SmartCraft system tachometer & speedometer installation.
COLOR DIAGRAMS
TYPICAL SMARTCRAFT SYSTEM MONITOR/TACHOMETER INSTALLATION WITH SYSTEM LINK GAUGES 2002 MODEL YEAR
Title page for SmartCraft system monitor/tachometer installation.
COLOR DIAGRAMS
TYPICAL SMARTCRAFT DUAL OUTBOARD INSTALLATION 2002 MODEL YEAR
Title page for SmartCraft dual outboard installation.
COLOR DIAGRAMS
150/175/200 EFI Oil & Fuel Flow 2002 Model Year
Title page for the oil and fuel flow diagram.
COLOR DIAGRAMS
150/175/200 EFI WATER FLOW DIAGRAM 2002 MODEL YEAR
Title page for the water flow diagram.
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