4s Efi 150 3.0 Litre

150 FourStroke
150
FourStroke
Serial Number 1B905505 and Above

90-8M0060785 DECEMBER 2011
Serial Number 1B905505 and Above
www.mercurymarine.com.au www.mercurymarine.com www.marinepower.com

41-71 Bessemer Drive P.O. Box 1939 Parc Industriel de Petit-Rechain
Dandenong South, Victoria 3175 Australia Fond du Lac, WI 54936-1939 USA B-4800 Verviers, Belgium
©2011, Mercury Marine. All rights reserved. Printed in U.S.A. 90-8M0060785 DECEMBER 2011
Notice to Users of This Manual
Throughout this publication, dangers, warnings, cautions, and notices (accompanied by the International HAZARD Symbol
! ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous
if performed incorrectly or carelessly. Observe them carefully!
These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when
performing the service, plus common sense operation, are major accident prevention measures.
! DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure.
IMPORTANT: Identifies information essential to the successful completion of the task.

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.
It is assumed that these personnel are familiar with marine product servicing procedures. Furthermore, it is assumed that they
have been trained in the recommended service procedures of Mercury Marine Power Products, including the use of mechanics’
common hand tools and the special Mercury Marine or recommended tools from other suppliers.
We could not possibly know of and advise the marine trade of all conceivable procedures and of the possible hazards and/or
results of each method. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the
manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered.
All information, illustrations, and specifications contained in this manual are based on the latest product information available at
the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service
these products.
Refer to dealer service bulletins, operation maintenance and warranty manuals, and installation manuals for other pertinent
information concerning the products described in this manual.
Precautions
It should be kept in mind, while working on the product, that the electrical and ignition systems are capable of violent and
damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be
grounded or touched by the mechanic, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental
entrance of foreign material into the cylinders which could cause extensive internal damage when the engine is started.
During any maintenance procedure, replacement fasteners must have the same measurements and strength as those
removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts
use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners
can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the
same locations whenever possible. Where the fasteners are not satisfactory for reuse, care should be taken to select a
replacement that matches the original.
Personnel should not work on or under an engine that is suspended. Engines should be attached to work stands, or lowered to
ground as soon as possible.
Page i
Replacement Parts
Use of parts other than the recommended service replacement parts will void the warranty on those parts that are damaged as
a result.
! WARNING
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.
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. This is considered standard shop practice even if not specifically stated.
Whenever components are removed for service, they should be retained in order. At the time of installation, they should be
installed in the same locations and with the same mating surfaces as when removed.
© 2011, Mercury Marine

Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers,
Mariner, Quicksilver, Alpha, Axius, Bravo One, Bravo Two, Bravo Three, K‑Planes, MerCathode, OptiMax, Precision Pilot, Pro
Max, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Total Command, Verado, VesselView, Zero Effort, Zeus, #1 On The Water, M
with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation.
Mercury Product Protection logo is a registered service mark of Brunswick Corporation.
Page ii
1
Manual Outline
Important Information
1 - Important Information
A - Master Specifications
B - Maintenance
C - General Information
Electrical
2
3
D - Outboard Installation
E - Storage Fuel System
2 - Electrical
A - Ignition
B - Charging and Starting Systems
C - Timing, Synchronizing, and Adjustments
Powerhead
4
5
D - Accessory Wire Diagrams
Midsection
3 - Fuel System
A - Theory of Operation
B - Troubleshooting and Diagnostics
C - Service Procedures
D - Emissions
Gear Housing
6
4 - Powerhead
A - Cylinder Block/Crankcase
B - Cylinder Head
Control Linkage and Attachments
7
C - Lubrication
D - Cooling
5 - Midsection
A - Clamp/Swivel Brackets and Driveshaft Housing
B - Adapter Plate and Driveshaft Housing
C - Power Trim
6 - Gear Housing
A - Right-Hand Rotation
B - Left-Hand Rotation
7 - Control Linkage and Attachments
A - Throttle Linkage
B - Shift Linkage
C - Cowl Latch
Page iii
Page iv
Notice to Users of This Manual
Throughout this publication, dangers, warnings, cautions, and notices (accompanied by the International HAZARD Symbol
! ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous
if performed incorrectly or carelessly. Observe them carefully!
These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when
performing the service, plus common sense operation, are major accident prevention measures.
! DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure.
IMPORTANT: Identifies information essential to the successful completion of the task.

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.
It is assumed that these personnel are familiar with marine product servicing procedures. Furthermore, it is assumed that they
have been trained in the recommended service procedures of Mercury Marine Power Products, including the use of mechanics’
common hand tools and the special Mercury Marine or recommended tools from other suppliers.
We could not possibly know of and advise the marine trade of all conceivable procedures and of the possible hazards and/or
results of each method. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the
manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered.
All information, illustrations, and specifications contained in this manual are based on the latest product information available at
the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service
these products.
Refer to dealer service bulletins, operation maintenance and warranty manuals, and installation manuals for other pertinent
information concerning the products described in this manual.
Precautions
It should be kept in mind, while working on the product, that the electrical and ignition systems are capable of violent and
damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be
grounded or touched by the mechanic, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental
entrance of foreign material into the cylinders which could cause extensive internal damage when the engine is started.
During any maintenance procedure, replacement fasteners must have the same measurements and strength as those
removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts
use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners
can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the
same locations whenever possible. Where the fasteners are not satisfactory for reuse, care should be taken to select a
replacement that matches the original.
Personnel should not work on or under an engine that is suspended. Engines should be attached to work stands, or lowered to
ground as soon as possible.
Page i
Replacement Parts
Use of parts other than the recommended service replacement parts will void the warranty on those parts that are damaged as
a result.
! WARNING
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. This is considered standard shop practice even if not specifically stated.
Whenever components are removed for service, they should be retained in order. At the time of installation, they should be
installed in the same locations and with the same mating surfaces as when removed.
© 2011, Mercury Marine

Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers,
Mariner, Quicksilver, Alpha, Axius, Bravo One, Bravo Two, Bravo Three, K‑Planes, MerCathode, OptiMax, Precision Pilot, Pro
Max, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Total Command, Verado, VesselView, Zero Effort, Zeus, #1 On The Water, M
with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation.
Mercury Product Protection logo is a registered service mark of Brunswick Corporation.
Page ii
1
Manual Outline
1 - Important Information
A - Master Specifications
B - Maintenance
C - General Information
Electrical
2
3
D - Outboard Installation
E - Storage Fuel System
2 - Electrical
A - Ignition
B - Charging and Starting Systems
C - Timing, Synchronizing, and Adjustments
Powerhead
4
5
D - Accessory Wire Diagrams
Midsection
3 - Fuel System
A - Theory of Operation
B - Troubleshooting and Diagnostics
C - Service Procedures
D - Emissions
Gear Housing
6
4 - Powerhead
A - Cylinder Block/Crankcase
B - Cylinder Head
7
C - Lubrication
D - Cooling
5 - Midsection
A - Clamp/Swivel Brackets and Driveshaft Housing
B - Adapter Plate and Driveshaft Housing
C - Power Trim
6 - Gear Housing
A - Right-Hand Rotation
B - Left-Hand Rotation
7 - Control Linkage and Attachments
A - Throttle Linkage
B - Shift Linkage
C - Cowl Latch
Page iii
Page iv
Master Specifications
1
Section 1A - Master Specifications A
Table of Contents
Master Specifications.........................................................1A-2 Cooling Specifications................................................ 1A-7
General Specifications................................................1A-2 Power Trim Specifications.......................................... 1A-7
Ignition Specifications................................................. 1A-3 Midsection Specifications........................................... 1A-7
Charging and Starting Specifications..........................1A-3 Gear Housing Specifications...................................... 1A-8
Fuel System Specifications.........................................1A-4 Gear Housing Specifications...................................... 1A-8
Cylinder Block/Crankcase Specifications................... 1A-5 Power Steering Specifications.................................... 1A-8
Cylinder Head Specifications......................................1A-6 Hydraulic Steering Specifications............................... 1A-9
Lubrication System Specifications.............................. 1A-7 Propeller Chart...................................................................1A-9
90-8M0060785 DECEMBER 2011 Page 1A-1

General Specifications
Model Specifications
Kilowatts (horsepower) 110 kW (150 hp)
Number of cylinders 4
Outboard weight
150 L 206 kg (454.15 lb)
150 XL/CXL 213 kg (470 lb)
Displacement 3.0 liter (183 in.³)
Cylinder bore 101.609 mm (4.0 in.)
Stroke 92.00 mm (3.62 in.)
RPM
Idle (in gear) 650 ± 50 RPM
WOT 5000–5800 RPM
Fuel system Computer controlled multi‑port electronic fuel injection
Ignition system SmartCraft engine control module (ECM) 70 digital inductive
Spark plug type NGK ZFR5F
Spark plug gap 0.8 mm (0.0314 in.)
Spark plug hex size 16 mm
Spark plug torque 27 Nm (20 lb‑ft)
Spark plug hole size 14 mm
Firing order 1‑3‑4‑2
Charging system Regulated belt driven 55 A alternator
Exhaust system Through‑the‑propeller
Cooling system Water‑cooled ‑ thermostat
Lubrication system
Integrated dry sump 6.0 liters (6.3 US qt)
Trim system
Maximum tilt range 73° (–6° to 67°)
Maximum trim range 20° (–6° to 14°)
Page 1A-2 90-8M0060785 DECEMBER 2011

Ignition Specifications
Full throttle RPM 5000–5800
Idle RPM 650 ± 50
Ignition type Digital inductive
Ignition timing at idle Approximately 2° BTDC; ECM controlled
Ignition timing at WOT ECM controlled
ECM overspeed limiter Activates at 5900 RPM
Charging and Starting Specifications

Alternator output (regulated)
Output at battery (at 1000 RPM) 23–30 A
Output at alternator (at 1000 RPM) 32–40 A
Voltage set point 14.4 ± 0.4 V
Ignition switch "OFF" 1.0 mA or less
Regulator current draw1.
Ignition switch "ON" 350 mA or less
Starter internal drive reduction ratio 6:1
Starter draw (under load) at 25 °C (77 °F) 150–225 A
Starter draw (no load) at 25 °C (77 °F) 50–70 A
Pull in coil 30 A
Hold coil 10 A
Starter solenoid
Pull in coil resistance 0.2 ± 10%
Hold coil resistance 0.8 ± 10%
Minimum brush length 6.54 mm (0.25 in.)
Starting battery rating
1000 minimum marine cranking
Required USA and Canada (SAE) starting battery type amps (MCA), 800 cold cranking
amps (CCA, or 180 amp hour (Ah)
1. All model alternator specifications require an amperage draw of less than 1.0 mA with the ignition key in the "OFF" position and an amperage
draw of not more than 350.0 mA with key in the "ON" position.
90-8M0060785 DECEMBER 2011 Page 1A-3

Fuel System Specifications

Automotive unleaded with a minimum pump posted octane rating of 87 (90
Type of fuel
RON)
Approximate fuel pressure at idle 280–310 kPa (40.6–45.0 psi)
Approximate fuel pressure engine not running 340–370 kPa (49.3–53.7 psi)
Fuel filtration
Fuel inlet 20 microns
High pressure 20 microns
Page 1A-4 90-8M0060785 DECEMBER 2011

Cylinder Block/Crankcase Specifications

Compression ratio 9.5:1
Standard bore finished hone 101.609 mm (4.0 in.)
Stroke 92.00 mm (3.62 in.)
Flatness 0.1 mm (0.0039 in.)
Cylinder deck
Surface tolerance Smooth and free of machine marks, nick, scratches
Crankcase deck
Cylinder bore maximum taper (service) 0.030 mm (0.0011 in.)
Cylinder bore maximum out of round (service) 0.050 mm (0.0019 in.)
A 60.989–60.997 mm (2.4011–2.4014 in.)
Cylinder block main bearing journal
B 60.998–61.005 mm (2.4014–2.4017 in.)
(letter)
C 61.006–61.013 mm (2.4018–2.4020 in.)
Crankshaft main bearing journal A 55.993–56.001 mm (2.2044–2.2047 in.)

(letter) B 55.985–55.993 mm (2.2041–2.2044 in.)
C 53.330–53.339 mm (2.0996–2.0999 in.)
Crankshaft connecting rod journal
D 53.321–53.329 mm (2.0992–2.0995 in.)
Crankshaft end play 0.0254–0.2794 mm (0.001–0.011 in.)
Crankshaft runout 0.05 mm (0.0019 in.)
Crankshaft main bearing oil clearance 0.052–0.086 mm (0.002–0.0033 in.)
Connecting rod piston pin bore diameter 22.016–22.026 mm (0.8667–0.8671 in.)
Journal grade "I" 56.508–56.514 mm (2.2247–2.2249 in.)
Connecting rod crankshaft pin diameter
Journal grade "0" 56.514–56.520 mm (2.2249–2.2251 in.)
Connecting rod bearing oil clearance 0.052–0.082 mm (0.002–0.0032 in.)
Piston skirt standard diameter 101.563–101.578 mm (3.9985–3.9991 in.)
Minimum 0.022 mm (0.0008 in.)
Piston to cylinder clearance
Maximum 0.046 mm (0.0018 in.)
Piston pin bore diameter 22.002–22.007 mm (0.8662–0.8664 in.)
Piston pin diameter 21.996–22.001 mm (0.8659–0.8661 in.)
First 1.520–1.545 mm (0.0598– 0.0608 in.)
Piston ring groove width Second 1.530–1.555 mm (0.0602– 0.0612 in.)
Third 3.0–3.025 mm (0.1181–0.1190 in.)
First 1.5 mm (0.059 in.)
Piston ring thickness
Second 1.5 mm (0.059 in.)
First 0.02–0.045 mm (0.0007–0.0017 in.)
Piston ring side clearance
Second 0.03–0.055 mm (0.0011–0.0021 in.)
First 0.25–0.40 mm (0.0098–0.0157 in.)
Piston ring end gap Second 0.46–0.66 mm (0.0181–0.0259 in.)
Third (lower ring only) 0.25–0.76 mm (0.0098–0.0299 in.)
90-8M0060785 DECEMBER 2011 Page 1A-5

Cylinder Head Specifications

Maximum warp 0.1 mm (0.0039 in.)
Deck
Minimum datum height (combustion chamber) 7 mm (0.275 in.)
Number of valves 8
Number of valves per cylinder 2
29.000–29.021 mm
Camshaft bearing inside diameter (cylinder head)
(1.1417–1.1425 in.)
19.975 ± 0.025 mm
Cylinder head camshaft center bearing thrust face
(0.7864 ± 0.0009 in.)
28.97 ± 0.01 mm
Camshaft bearing journal
(1.1405 ± 0.0004 in.)
Intake 48.05 mm (1.892 in.)
Camshaft lobe height
Exhaust 49.1 mm (1.933 in.)
Camshaft to roller clearance Intake 0.0762 mm (0.003 in.)

(lash) Exhaust 0.254 mm (0.010 in.)
Intake 30°, 44°, 60°
Valve seat angles
Exhaust 25°, 44°, 65°
Intake 1.02 ± 0.1 mm (0.04 ± 0.0039 in.)
Valve seat width (44°)
Exhaust 1.8 ± 0.1 mm (0.07 ± 0.0039 in.)
57.08 ± 0.25 mm
Uncompressed
(2.247 ± 0.0098 in.)
350 ± 25 N (78.68 ± 5.62 lbf)
Valve spring height Compressed to 50.24 mm (1.977 in.)
spring pressure
1039 ± 45 N (233.57 ± 10.11 lbf)
Compressed to 36.78 mm (1.448 in.)
spring pressure
Intake 50.8 ± 0.13 mm (2.0 ± 0.005 in.)
Valve outside diameter
Exhaust 39.4 ± 0.13 mm (1.55 ± 0.005 in.)
Valve face angle Intake and exhaust 45°
0.38 ± 0.2 mm
Intake
(0.0149 ± 0.007 in.)
Valve margin width
1.46 ± 0.35 mm
Exhaust
(0.0574 ± 0.0137 in.)
7.966 ± 0.01 mm
Valve stem diameter Intake and exhaust
(0.313 ± 0.0003 in.)
Valve stem runout (service limit
Intake and exhaust 0.038 mm (0.0015 in.)
measured at valve face)
125.14 ± 0.30 mm
Intake
(4.9267 ± 0.0118 in.)
Valve height
126.29 ± 0.30 mm
Exhaust
(4.9720 ± 0.0118 in.)
8.001–8.021 mm
Valve guide bore inside diameter Intake and exhaust
(0.3149–0.3157 in.)
Valve stem to valve guide 0.025–0.065 mm
Intake and exhaust
clearance (0.001–0.0025 in.)
24.9 ± 0.25 mm
Valve guide height Intake and exhaust
(0.980 ± 0.0098 in.)
Page 1A-6 90-8M0060785 DECEMBER 2011

Lubrication System Specifications

Engine capacity with filter replacement 6 liters (6.3 US qt)
Oil filter P/N 35‑877761K1
At idle RPM (oil cold to warm) 152–303 kPa (22–44 psi)
At WOT RPM (oil cold to warm) 372–476 kPa (54–69 psi)
Oil pressure
At idle RPM (oil hot) 76–152 kPa (11–22 psi)
At WOT RPM (oil hot) 276–373 kPa (40–54 psi)
Cooling Specifications
Cooling system Water‑cooled ‑ thermostat control
At 650 RPM (idle) 5–30 kPa (0.7–4.4 psi)
Water pressure
At 5800 RPM (WOT) 80–300 kPa (11.6–43.5 psi)
Valve stroke (minimum) at full open temperature 7.62 mm (0.30 in.)
Thermostat Start to opening temperature 46.1–51.7 °C (115–125 °F)
Full open temperature 65.6 °C (150 °F)
Power Trim Specifications

Power Trim Specifications
Trim up relief valve ‑ tilt extended relief pressure 18,600 kPa (2700 psi) minimum
Trim down relief valve pressure 3730–6150 kPa (540–890 psi)
Power Trim and Steering Fluid or automatic transmission fluid (ATF) Type
System fluid
F, FA, Dexron II, or Dexron III
Midsection Specifications
Midsection Specifications
Recommended transom height
Long shaft 508 mm (20 in.)
XL shaft 635 mm (25 in.)
Tiller 60°
Steering pivot range
Remote 60°
Full tilt up angle 71°
Trim angle (on 12° boat transom) Negative 4° to positive 16°
Allowable transom thickness (maximum) 70 mm (2.75 in.)
90-8M0060785 DECEMBER 2011 Page 1A-7

Gear Housing Specifications

Right‑Hand Gear Housing Specifications
Gear ratio 1.92:1 (13/25 teeth)
Gear housing capacity 780 ml (26.4 fl oz)
Gear lubricant type High Performance Gear Lubricant
Propeller shaft runout 0.152 mm (0.006 in.)
Propeller shaft end play 0.127–1.905 mm (0.005–0.075 in.)
Pinion height 0.635 mm (0.025 in.)
Forward gear backlash 0.457–0.610 mm (0.018–0.024 in.)
Reverse gear backlash 0.305–0.838 mm (0.012–0.033 in.)
Water pressure
At 5800 RPM (WOT) 80–300 kPa (11.6–43.5 psi)
Gear housing leak test (without gear lubricant, 15 minutes without leakage) 103.4 kPa (15 psi)
Gear Housing Specifications

Left‑Hand Gear Housing Specifications
Gear ratio 1.92:1 (13/25 teeth)
Gear housing capacity 545 ml (18.4 fl oz)
Gear lubricant type High Performance Gear Lubricant
Propeller shaft runout 0.152 mm (0.006 in.)
Propeller shaft end play 0.330–1.22 mm (0.013–0.048 in.)
Pinion height 0.635 mm (0.025 in.)
Forward gear backlash 0.483–0.610 mm (0.019–0.024 in.)
Reverse gear backlash 0.533–0.813 mm (0.021–0.032 in.)
Water pressure
At 5800 RPM (WOT) 80–300 kPa (11.6–43.5 psi)
Gear housing leak test (without gear lubricant, 15 minutes without leakage) 103.4 kPa (15 psi)
Power Steering Specifications

Power Steering Specifications
Synthetic Power Steering Fluid
Fluid type
SAE 0W‑30
Capacity Typical 1–2 liters (1–2 US qt)
Current draw Not to exceed 75 A
Steering ratio (32 cc helm and single steering cylinder, lock to lock) ‑ preferred configuration 3.8 turns
Steering ratio (40 cc helm and single steering cylinder, lock to lock) 3.0 turns
Steering ratio (32 cc helm with dual steering cylinders, lock to lock) 7.6 turns
Steering ratio (40 cc helm with dual steering cylinders, lock to lock) ‑ preferred configuration 6.0 turns
Page 1A-8 90-8M0060785 DECEMBER 2011

Hydraulic Steering Specifications

Hydraulic Steering Specifications
Fluid type Hydraulic Helm Steering Fluid
Steering ratio (28 cc helm and single steering cylinder, lock to lock) ‑ preferred configuration 4.3 turns
Steering ratio (39 cc helm with dual steering cylinders, lock to lock) ‑ preferred configuration 6.2 turns
Propeller Chart
Mercury/Mariner 150 EFI FourStroke
• Wide‑open throttle RPM: 5000–5800
• Recommended transom heights: 50.8 cm (20 in.), 63.5 cm (25 in.)
• Gear ratio: 1.92:1
• Right‑hand rotation (RH), left‑hand rotation (LH)
• Aluminum (al)
Diameter No. of Approx. Gross Boat Approx. Boat Propeller Part

Pitch Model Speed Range
(inches) Blades Wgt. Length Number
Trophy Up to 952.54 kg Up to 5.79 m 93.34–109.43 km/h
13.75 26 4 48‑825944A47
Plus (2100 lb) (19 ft) (58–68 mph)
Up to 952.54 kg Up to 5.79 m 93.34–109.43 km/h
14.00 26 3 Fury 48‑8M8023160
(2100 lb) (19 ft) (58–68 mph)
Tempest Up to 952.54 kg Up to 5.79 m 93.34–109.43 km/h
14.62 26 3 48‑825874A47
Plus (2100 lb) (19 ft) (58–68 mph)
Trophy 816.46–997.9 kg 5.18–5.79 m 88.51–104.6 km/h
13.75 25 4 48‑825942A47
Plus (1800–2200 lb) (17–19 ft) (55–65 mph)
816.46–997.9 kg 5.18–5.79 m 88.51–104.6 km/h
14.00 25 3 Fury 48‑8M8023140
(1800–2200 lb) (17–19 ft) (55–65 mph)
Tempest 816.46–997.9 kg 5.18–5.79 m 88.51–104.6 km/h
14.62 25 3 48‑825866A47
Plus (1800–2200 lb) (17–19 ft) (55–65 mph)
816.46–997.9 kg 5.18–5.79 m 88.51–104.6 km/h
13.25 25 5 HighFive 48‑816374A46
(1800–2200 lb) (17–19 ft) (55–65 mph)
816.46–997.9 kg 5.18–5.79 m 88.51–104.6 km/h 48‑16550A46 (RH)
13.75 25 3 Laser II
(1800–2200 lb) (17–19 ft) (55–65 mph) 48‑16549A46 (LH)
Trophy 907.18–1088.62 kg 5.48–6.09 m 93.34–104.6 km/h
13.75 24 4 48‑825940A47
Plus (1900–2300 lb) (18–20 ft) (53–62 mph)
907.18–1088.62 kg 5.48–6.09 m 93.34–104.6 km/h
14.00 24 3 Fury 48‑8M8023120
(1900–2300 lb) (18–20 ft) (53–62 mph)
Tempest 861.85–1043.26 kg 5.48–6.09 m 93.34–104.6 km/h
14.62 24 3 48‑825872A47
Plus (1900–2300 lb) (18–20 ft) (53–62 mph)
Trophy 907.18–1088.62 kg 5.48–6.09 m 80.46–96.56 km/h
13.75 23 4 48‑825938A47
Plus (2000–2400 lb) (18–20 ft) (50–60 mph)
Tempest 907.18–1088.62 kg 5.48–6.09 m 80.46–96.56 km/h 48‑825864A47 (RH)
14.62 23 3
Plus (2000–2400 lb) (18–20 ft) (50–60 mph) 48‑825865A47 (LH)
907.18–1088.62 kg 5.48–6.09 m 80.46–96.56 km/h
13.25 23 5 HighFive 48‑815762A46
(2000–2400 lb) (18–20 ft) (50–60 mph)
90-8M0060785 DECEMBER 2011 Page 1A-9


48‑825906A48
907.18–1088.62 kg 5.48–6.09 m 80.46–96.56 km/h
14.00 23 4 VenSura (RH)48‑825907A48
(2000–2400 lb) (18–20 ft) (50–60 mph)
(LH)
907.18–1088.62 kg 5.48–6.09 m 80.46–96.56 km/h 48‑16320A46 (RH)
13.5 23 3 Vengence
(2000–2400 lb) (18–20 ft) (50–60 mph) 48‑16321A46 (LH)
907.18–1088.62 kg 5.48–6.09 m 80.46–96.56 km/h 18‑16548A46 (RH)
13.75 23 3 Lazer II
(2000–2400 lb) (18–20 ft) (50–60 mph) 48‑16547A46 (LH)
Black Max 907.18–1088.62 kg 5.48–6.09 m 80.46–96.56 km/h
14.00 23 3 48‑832834A45
(al) (2000–2400 lb) (18–20 ft) (50–60 mph)
Tempest 952.54–1179.34 kg 5.48–6.4 m 75.64–91.73 km/h
14.62 22 3 48‑8M8026820
Plus (2100–2600 lb) (18–21 ft) (47–57 mph)
952.54‑1179.34 kg 5.48–6.4 m 75.64–91.73 km/h
13.50 22 3 Enertia 48‑899202A46
(2100–2600) (18–21 ft) (47–57 mph)
Trophy 997.9–1270.05 kg 5.48–6.4 m 70.81–86.9 km/h
13.75 21 4 48‑825934A47
Plus (2200–2800 lb) (18–21 ft) (44–54 mph)
48‑825862A47
Tempest 997.9–1270.05 kg 5.48–6.4 m 70.81–86.9 km/h
14.62 21 3 (RH)48‑825863A47
Plus (2200–2800 lb) (18–21 ft) (44–54 mph)
(LH)
48‑899002A46
997.9–1270.05 kg 5.48–6.4 m 70.81–86.9 km/h
13.62 21 3 Enertia (RH)48‑899003A46
(2200–2800 lb) (18–21 ft) (44–54 mph)
(LH)
Mirage 997.9–1270.05 kg 5.48–6.4 m 70.81–86.9 km/h 48‑13702A46 (RH)
14.75 21 3
Plus (2200–2800 lb) (18–21 ft) (44–54 mph) 48‑13703A46 (LH)
997.9–1270.05 kg 5.48–6.4 m 70.81–86.9 km/h
13.25 21 5 HighFive 48‑815760A46
(2200–2800 lb) (18–21 ft) (44–54 mph)
997.9–1270.05 kg 5.48–6.4 m 70.81–86.9 km/h 48‑825902A48 (RH)
14.00 21 4 VenSura
(2200–2800 lb) (18–21 ft) (44–54 mph) 48‑825903A48 (LH)
997.9–1270.05 kg 5.48–6.4 m 70.81–86.9 km/h 48‑16318A46 (RH)
13.75 21 3 Vengence
(2200–2800 lb) (18–21 ft) (44–54 mph) 48‑16319A46 (LH)
Black Max 997.9–1270.05 kg 5.48–6.4 m 70.81–86.9 km/h
14.25 21 3 48‑832832A45
(al) (2200–2800 lb) (18–21 ft) (44–54 mph)
1043.26–1179.34 kg 5.79–6.7 m 67.59–83.68 km/h
13.75 20 3 Enertia 48‑899000A46
(2300–3000 lb) (19–22 ft) (42–52 mph)
1043.26–1179.34 kg 5.79–6.7 m 67.59–83.68 km/h 48‑834854A45 (RH)
14.00 20 4 Alpha 4 (al)
(2300–3000 lb) (19–22 ft) (42–52 mph) 48‑834855A45 (LH)
Tempest 1133.98–1451.50 kg 5.79–6.7 m 62.76–78.85 km/h 48‑825860A47 (RH)
14.62 19 3
Plus (2500–3200 lb) (19–22 ft) (39–49 mph) 48‑825861A47 (LH)
1133.98–1451.50 kg 5.79–6.7 m 62.76–78.85 km/h 48‑898998A46 (RH)
14.00 19 3 Enertia
(2500–3200 lb) (19–22 ft) (39–49 mph) 48‑898999A46 (LH)
15.25 19 3
Plus (2500–3200 lb) (19–22 ft) (39–49 mph) 48‑13701A46 (LH)
1133.98–1451.50 kg 5.79–6.7 m 62.76–78.85 km/h
13.25 19 5 HighFive 48‑815758A46
(2500–3200 lb) (19–22 ft) (39–49 mph)
1133.98–1451.50 kg 5.79–6.7 m 62.76–78.85 km/h 48‑825900A48 (RH)
14.00 19 4 VenSura
(2500–3200 lb) (19–22 ft) (39–49 mph) 48‑825901A48 (LH)
1133.98–1451.50 kg 5.79–6.7 m 62.76–78.85 km/h 48‑16316A46 (RH)
14.00 19 3 Vengence
(2500–3200 lb) (19–22 ft) (39–49 mph) 48‑16317A46 (LH)
Black Max 1088.62–1270.05 kg 5.79–6.7 m 62.76–78.85 km/h
14.50 19 3 48‑832830A45
(al) (2500–3200 lb) (19–22 ft) (39–49 mph)
Page 1A-10 90-8M0060785 DECEMBER 2011


1224.69–1632.93 kg 5.79–7.01 m 56.32–74.02 km/h
14.25 18 3 Enertia 48‑898996A46
(2700–3600 lb) (19–23 ft) (35–46 mph)
15.38 18 3
Plus (2700–3600 lb) (19–23 ft) (35–46 mph) 48‑889619A46 (LH)
1224.69–1632.93 kg 5.79–7.01 m 56.32–74.02 km/h 48‑834852A45 (RH)
14.50 18 4 Alpha 4 (al)
(2700–3600 lb) (19–23 ft) (35–46 mph) 48‑834853A45 (LH)
15.50 17 3
Plus (2900–4000 lb) (19–23 ft) (32–43 mph) 48‑90159A46 (LH)
Tempest 1315.41–1814.36 kg 5.79–7.01 m 51.49–69.2 km/h
14.62 17 3 48‑8M8026790
Plus (2900–4000 lb) (19–23 ft) (32–43 mph)
1315.41–1814.36 kg 5.79–7.01 m 51.49–69.2 km/h 48‑898994A46 (RH)
14.50 17 3 Enertia
(2900–4000 lb) (19–23 ft) (32–43 mph) 48‑898995A46 (LH)
1315.41–1814.36 kg 5.79–7.01 m 51.49–69.2 km/h
13.50 17 5 HighFive 48‑821154A46
(2900–4000 lb) (19–23 ft) (32–43 mph)
1315.41–1814.36 kg 5.79–7.01 m 51.49–69.2 km/h 48‑825898A48 (RH)
14.25 17 4 VenSura
(2900–4000 lb) (19–23 ft) (32–43 mph) 48‑825899A48 (LH)
1315.41–1814.36 kg 5.79–7.01 m 51.49–69.2 km/h 48‑16314A46 (RH)
14.50 17 3 Vengence
(2900–4000 lb) (19–23 ft) (32–43 mph) 48‑16315A46 (LH)
Black Max 1315.41–1814.36 kg 5.79–7.01 m 51.49–69.2 km/h
15.00 17 3 48‑832828A45
(al) (2900–4000 lb) (19–23 ft) (32–43 mph)
1406.13–1723.65 kg 6.09–7.31 m 46.67–64.37 km/h
14.75 16 3 Enertia 48‑898992A46
(3100–4500 lb) (20–24 ft) (29–40 mph)
1406.13–1723.65 kg 6.09–7.31 m 46.67–64.37 km/h 48‑834850A45 (RH)
15.00 16 4 Alpha 4 (al)
(3100–4500 lb) (20–24 ft) (29–40 mph) 48‑834851A45 (LH)
1542.2–23133.3 kg 6.4–7.62 m 41.84–59.54 km/h 48‑898990A46 (RH)
15.00 15 3 Enertia
(3400–5100 lb) (21–25 ft) (26–37 mph) 48‑898991A46 (LH)
15.75 15 3
Plus (3400–5100 lb) (21–25 ft) (26–37 mph) 48‑19841A46 (LH)
Revolution 1542.2–2313.3 kg 6.4–7.62 m 41.84–59.54 km/h
14.62 15 4 48‑857022A46
4 (3400–5100 lb) (21–25 ft) (26–37 mph)
Black Max 1542.2–2313.3 kg 6.4–7.62 m 41.84–59.54 km/h
15.25 15 3 48‑78116A45
(al) (3400–5100 lb) (21–25 ft) (26–37 mph)
1542.2–2313.3 kg 6.4–7.62 m 41.84–59.54 km/h
15.13 14 3 Enertia 48‑898988A46
(3400–5100 lb) (21–25 ft) (26–37 mph)
Mirage 1905.08–2540.17 kg 6.7–8.53 m 30.57–49.88 km/h
16 13 3 48‑826072A46
Plus (4200–7300 lb) (22–28 ft) (19–31 mph)
Black Max 1905.08–2540.17 kg 6.7–8.53 m 30.57–49.88 km/h
16 13 3 48‑78114A45
(al) (4200–7300 lb) (22–28 ft) (19–31 mph)
Black Max 2721.55+ kg Pontoon/ 19.31–40.23 km/h
16 12 3 48‑16436A45
(al) (6000+ lb) Work (12–25 mph)
Black Max 3175.14+ kg 1.6–37.0` km/h 48‑78112A45 (RH)
16 11 3 Work
(al) (8000+ lb) (1–23 mph) 48‑78117A40 (LH)
90-8M0060785 DECEMBER 2011 Page 1A-11

Notes:
Page 1A-12 90-8M0060785 DECEMBER 2011

Maintenance
1
Section 1B - Maintenance B
Table of Contents
General Specifications....................................................... 1B-2 Propeller Replacement...................................................... 1B-8
EPA Emissions Regulations.............................................. 1B-3 Flo‑Torq II Propellers.................................................. 1B-9
Emission Certification Label....................................... 1B-3 Flo‑Torq IV Propellers.................................................1B-9
Owner Responsibility.................................................. 1B-3 Spark Plug Inspection and Replacement.........................1B-10
Inspection and Maintenance Schedule.............................. 1B-3 Fuse Replacement...........................................................1B-10
Before Each Use.........................................................1B-3 Alternator Belt.................................................................. 1B-11
After Each Use............................................................1B-3 Alternator Drive Belt Inspection................................ 1B-11
Every 100 Hours of Use or Once Yearly, Whichever Alternator Belt Failure Identification..........................1B-12
Occurs First.............................................................1B-4 Alternator Belt Replacement.....................................1B-13
Every 300 Hours of Use or Three Years.....................1B-4 Lubrication Points............................................................ 1B-15
Before Periods of Storage.......................................... 1B-4 Checking Power Trim Fluid..............................................1B-16
Flushing the Cooling System............................................. 1B-4 Checking and Adding Engine Oil..................................... 1B-17
Top Cowl Removal and Installation................................... 1B-5 Changing Engine Oil ....................................................... 1B-18
Removal......................................................................1B-5 Engine Oil Capacity.................................................. 1B-18
Installation...................................................................1B-5 Oil Changing Procedure........................................... 1B-18
Cleaning Care for Top and Bottom Cowls......................... 1B-5 Changing Oil Filter ................................................... 1B-18
Cleaning and Waxing Procedure................................ 1B-5 Oil Filling................................................................... 1B-19
Cleaning Care for the Powerhead (Saltwater Use)............1B-6 Gearcase Lubrication.......................................................1B-19
Battery Inspection ............................................................. 1B-6 Gearcase Lubricant Capacity................................... 1B-19
Fuel System....................................................................... 1B-6 Draining Gearcase....................................................1B-19
Fuel Line Inspection....................................................1B-6 Gearcase Lubricant Recommendation..................... 1B-20
Low‑Pressure Fuel Filter.............................................1B-6 Checking Lubricant Level and Refilling Gearcase.... 1B-20
Corrosion Control Anode................................................... 1B-7 Submerged Outboard...................................................... 1B-20
90-8M0060785 DECEMBER 2011 Page 1B-1

Maintenance
General Specifications
Model Specifications
Kilowatts (horsepower) 110 kW (150 hp)
Outboard weight
150 L 206 kg (454.15 lb)
150 XL/CXL 213 kg (470 lb)
Cylinder bore 101.609 mm (4.0 in.)
Stroke 92.00 mm (3.62 in.)
RPM
Idle (in gear) 650 ± 50 RPM
WOT 5000–5800 RPM
Fuel system Computer controlled multi‑port electronic fuel injection
Ignition system SmartCraft engine control module (ECM) 70 digital inductive
Charging system Regulated belt driven 55 A alternator
Exhaust system Through‑the‑propeller
Cooling system Water‑cooled ‑ thermostat
Lubrication system
Integrated dry sump 6.0 liters (6.3 US qt)
Trim system
Maximum tilt range 73° (–6° to 67°)
Maximum trim range 20° (–6° to 14°)
Lubricants, Sealants, Adhesives

Tube Ref No. Description Where Used Part No.
34 Special Lubricant 101 Steering cable 92-802865Q02
81 Anti-Seize Compound Spark plug threads 92-898101385
94 Anti-Corrosion Grease Propeller shaft 92-802867Q 1

Propeller shaft
95 2-4-C with PTFE 92-802859A 1
Steering cable
Power Trim and Steering
114 Power trim reservoir 92-858074K01
Fluid
External metal surfaces of the powerhead and powerhead
120 Corrosion Guard 92-802878 55
components.
Page 1B-2 90-8M0060785 DECEMBER 2011

Maintenance
EPA Emissions Regulations

All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as
conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is
contingent on certain adjustments set to factory standards. For this reason, the factory procedure for servicing the product must
be strictly followed and, wherever practicable, returned to the original intent of the design. Maintenance, replacement, or repair
of the emission control devices and systems may be performed by any marine spark ignition (SI) engine repair establishment or
individual.
Emission Certification Label

An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the
engine at the time of manufacture.
EMISSION CONTROL
a INFORMATION
f a- Idle speed
THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA
g b- Engine horsepower
b
EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE,
SPECIFICATIONS, AND ADJUSTMENTS c- Piston displacement
c IDLE SPEED (in gear): FAMILY:
h d- Engine power ‑ kilowatts
hp L HC+NOx:FEL: g/kWh
d e- Date of manufacture
kw CO FEL: g/kWh
i
f- Family number
SPARK PLUG:
GAP:
e LOW PERM/HIGH PERM: j g- Regulated emission limit for the engine family
43210
h- Regulated emission limit for the engine family
i- Recommended spark plug and gap
j- Percent of fuel line permeation
Owner Responsibility
The owner/operator is required to have routine engine maintenance performed to maintain emission levels within prescribed
certification standards.
The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to
exceed their predetermined factory specifications.
Inspection and Maintenance Schedule

Before Each Use
• Check the engine oil level. Refer to Checking and Adding Engine Oil.
• Verify the lanyard stop switch stops the engine.
• Inspect the outboard for tightness to the boat transom. If any looseness of the outboard or mounting fasteners exist,
retorque the outboard mounting fasteners to the specified torque. When looking for signs of looseness, look for loss of
outboard transom bracket material or paint caused by movement between the outboard mounting fasteners and the
outboard transom brackets. Also look for signs of movement between the outboard transom brackets and the boat transom
(lift plate/setback bracket).
Description Nm lb‑in. lb‑ft

Outboard mounting locknuts and bolts ‑ standard boat transom 75 55
Outboard mounting locknuts and bolts ‑ metal lift plates and setback brackets 122 90
• Visually inspect the fuel system for deterioration or leaks.
• Check the steering system for binding or loose components.
• Check the propeller blades for damage.
After Each Use

• Flush out the outboard cooling system if operating in salt, polluted, or muddy water. Refer to Flushing the Cooling System.
• Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase with fresh water if operating in
saltwater.
• When operating in saltwater, inspect the powerhead and powerhead components for salt buildup. Refer to Cleaning Care
for the Powerhead (Saltwater Use).
90-8M0060785 DECEMBER 2011 Page 1B-3

Maintenance
Every 100 Hours of Use or Once Yearly, Whichever Occurs First

• Change the engine oil and replace the oil filter. The oil should be changed more often when the engine is operated under
adverse conditions, such as extended trolling. Refer to Changing Engine Oil.
• Inspect the thermostat visually for corrosion or damage. Make sure the thermostat closes completely at room temperature.
1.
• Check the low‑pressure fuel filter for contaminants. Replace filter if required. Refer to Fuel System.
• Check the torque of the fasteners that secure the outboard to the boat transom or setback bracket. Tighten the fasteners to
the specified torque.1.

• Check the corrosion control anodes. Check more frequently when used in saltwater. Refer to Corrosion Control Anode.
• Drain and replace the gearcase lubricant. Refer to Gearcase Lubrication.
• Inspect battery. Refer to Battery Inspection.
• In saltwater usage, remove spark plugs and apply a thin coating of Anti‑Seize Compound only on the threads of the spark
plugs. Reinstall spark plugs. Refer to Spark Plug Inspection and Replacement.

• Check wiring and connectors.
• Check tightness of bolts, nuts, and other fasteners.
• Check cowl seals to ensure seals are intact and not damaged.
• Check internal cowl sound reduction foam (if equipped) to ensure foam is intact and not damaged.
• Verify that the intake silencer (if equipped) is in place.
• Verify that the idle relief muffler (if equipped) is in place.
• Check for loose hose clamps and rubber boots (if equipped) on the air intake assembly.
Every 300 Hours of Use or Three Years

• Check power trim fluid. Refer to Checking Power Trim Fluid.
• Replace water pump impeller (more often if overheating occurs or reduced water pressure is noted).1.
• Lubricate the splines on the upper driveshaft.1.
• Replace alternator drive belt. Refer to Alternator Drive Belt Inspection.1.
Before Periods of Storage

• Refer to Storage section.
Flushing the Cooling System

Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will
help prevent a buildup of deposits from clogging the internal water passages.
NOTE: The outboard can be tilted or in the vertical operating position during flushing.
1. With the engine turned off, place the outboard in either the operating position (vertical) or in a tilted position.
2. Remove the flush connector from the bottom cowl.
1. These items should be serviced by an authorized dealer.
Page 1B-4 90-8M0060785 DECEMBER 2011

Maintenance
3. Remove the cover from the flush connector and thread a water hose into the flush connector.
47592
4. Turn on the water tap (1/2 maximum) and let the water flush through the cooling system for about 15 minutes.
5. When flushing is complete, turn off water and disconnect the water hose.
6. Install the cover on the flush connector. Place the flush connector into the bottom cowl.
Top Cowl Removal and Installation

Removal
Unlock the top cowl by pulling out on the rear cowl latch. Lift the top cowl off the engine.
47632
Installation
1. Lower the top cowl into position over the engine.
2. Bring the front of the cowl down first and engage the front cowl hook. Lower the cowl into the seated position and apply
pressure to the back of the cowl to lock it in place. Ensure the cowl is securely fastened by trying to pull up on the back of
the cowl.
47633
Cleaning Care for Top and Bottom Cowls

IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches. Always wet the
surface before cleaning. Do not use detergents containing hydrochloric acid. Follow the cleaning and waxing procedure.
Cleaning and Waxing Procedure

1. Before washing, rinse the cowls with clean water to remove dirt and dust that may scratch the surface.
2. Wash the cowls with clean water and a mild nonabrasive soap. Use a soft clean cloth when washing.
90-8M0060785 DECEMBER 2011 Page 1B-5

Maintenance
3. Dry thoroughly with a soft clean cloth.

4. Wax the surface using a nonabrasive automotive polish (polish designed for clear coat finishes). Remove the applied wax
by hand using a clean soft cloth.
5. To remove minor scratches, use Mercury Marine Cowl Finishing Compound (92‑859026K 1).
Cleaning Care for the Powerhead (Saltwater Use)

If the outboard is operated in saltwater, remove the top cowl and flywheel cover. Inspect the powerhead and powerhead
components for salt buildup. Wash off any salt buildup from the powerhead and powerhead components with fresh water. 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.
IMPORTANT: Do not allow lubricant or Corrosion Guard spray to come in contact with the alternator drive belt or the belt
pulleys. The alternator drive belt could slip and be damaged if it becomes coated with any lubricant or Corrosion Guard spray.

External metal surfaces of the powerhead and powerhead
120 Corrosion Guard 92-802878 55
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.
1. Turn off the engine before servicing the battery.
2. Ensure the battery is secure against movement.
3. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative.
4. Ensure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals.
Fuel System
! WARNING
Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot
start. 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.
IMPORTANT: Use an approved container to collect and store fuel. Wipe up spilled fuel immediately. Material used to contain
spilled fuel must be disposed of in an approved receptacle.
Before servicing any part of the fuel system:
1. Stop engine and disconnect the battery.
2. Perform fuel system service in a well‑ventilated area.
3. Inspect any completed service work for sign of fuel leakage.
Fuel Line Inspection

Visually inspect the fuel line for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these
conditions are found, the fuel line must be replaced.
Low‑Pressure Fuel Filter

The low‑pressure filter can be serviced as a general maintenance item. However, the high‑pressure filter should only be
serviced by an authorized dealer.
Removal
1. Turn the ignition key switch to the "OFF" position.
Page 1B-6 90-8M0060785 DECEMBER 2011

Maintenance
2. Move the lift handle so that the locking tab clears the bracket.
b a - Lift handle
b - Locking tab secured under bracket
a
47535
3. Use the lift handle and pull the fuel filter out of its opening. If necessary, move the fuel hose so that it clears the bracket
while lifting the fuel filter.
4. Push on the fuel hose release tabs and disconnect the fuel hoses from the fuel filter.
5. Place the lower hose into the hose holder to prevent it from dropping into the filter hole.
6. Remove the fuel filter from the lift handle.
a - Fuel hose release tab

b - Low‑pressure fuel filter
c - Hose holder
b
a
c 47441
Installation
1. Place the lift handle onto the fuel filter. Install the new fuel filter so the arrow points towards the engine.
2. Connect the fuel hoses to the fuel filter securely with the locking hose connections.
3. Visually inspect for fuel leakage from the fuel filter while turning the ignition key to the "RUN" position. Repair any fuel
leaks, if necessary.
4. Install the fuel filter back into the opening. Position the lift handle so that the locking tab is secured under the bracket.
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.
All anodes require periodic inspection, especially in saltwater. To maintain corrosion protection, always replace the anode
before it is 50% consumed. Never paint or apply a protective coating on the anode. This will reduce the effectiveness of the
anode.
90-8M0060785 DECEMBER 2011 Page 1B-7

Maintenance
Two anodes are located on each side of the gear housing. Another anode is installed on the bottom of the transom bracket
assembly.
47569
Propeller Replacement
! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
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.
1. Shift outboard to the neutral (N) position.
26838
2. Straighten the bent tabs on the propeller nut retainer.

3. Place a block of wood between the gearcase and the propeller to hold the propeller and remove the propeller nut.
26901
4. Pull the propeller straight off the shaft. If the propeller is seized to the shaft and cannot be removed, have the propeller
removed by an authorized dealer.
Page 1B-8 90-8M0060785 DECEMBER 2011

Maintenance
5. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE.
47623

95 2-4-C with PTFE Propeller shaft 92-802859A 1
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.
Flo‑Torq II Propellers
1. Install the propeller onto the shaft with the supplied components as shown.
2. Place the locknut retainer over the raised pins on the drive sleeve adapter and tighten the locknut to the specified torque.
3. Secure the locknut by bending the tabs up against the locknuts.
c
a a- Forward thrust washer
b h b- Drive sleeve
d e g
c- Propeller
d- Drive sleeve adapter
e- Locknut retainer
f- Locknut
g- Raised pins
f 45232 h- Tabs bent against the locknut

Propeller nut 75 55
Flo‑Torq IV Propellers
1. Install the propeller onto the shaft with the supplied components as shown.
2. Tighten the locknut to the specified torque.
3. Secure the locknut by bending three of the tabs into the grooves in the drive sleeve adapter.
c
a- Forward thrust washer
a b b- Drive sleeve
d e g
c- Propeller
d- Drive sleeve adapter
e- Locknut retainer
f- Locknut
g- Tabs bent into grooves
f 45248

Propeller nut 75 55
90-8M0060785 DECEMBER 2011 Page 1B-9

Maintenance
Spark Plug Inspection and Replacement

1. Pull the rubber boots off the spark plugs.
47660
2. Remove the spark plugs to inspect.
47662
3. Inspect each spark plug for a worn or fouled electrode, corroded metal body, insulator that is rough, cracked, broken, or
blistered. Set the spark plug gap to specifications.
27848
Spark Plug
4. Saltwater use ‑ Apply a thin coating of Anti‑Seize Compound only on threads of spark plugs.

5. Before installing spark plugs, clean off any dirt on the spark plug seats. Install the plugs finger‑tight, then tighten 1/4 turn or
torque to specifications.

Spark plug 27 20
Fuse Replacement
IMPORTANT: Always carry spare fuses.
The electrical wiring circuits on the outboard are protected from overload with fuses. If a fuse is blown, locate and correct the
cause of the overload. If the cause is not found, the fuse may blow again.
Page 1B-10 90-8M0060785 DECEMBER 2011

Maintenance
Open the fuse holder and look at the silver colored band inside the fuse. If the band is broken, replace the fuse. Replace fuse
with a new fuse with the same rating.
a- Cover
b b- Spare fuse holders
c- Fuse holder
a d- Fuse 4 ‑ IGN. 20 amp ‑ ignition system
e- Fuse 2 ‑ FUEL 20 amp ‑ fuel delivery
f- Fuse 1 ‑ DIAG. 2 amp ‑ diagnostics/vessel (accessory)
harness
g - Fuse 3 ‑ HELM 15 amp ‑ 14 pin remote control harness/
cowl trim switch
c
h - Good fuse
i - Blown fuse
h
g d
20
15
i 20
2
f e
47408
Alternator Belt
Alternator Drive Belt Inspection
1. Remove the three screws securing the flywheel cover to the engine. Lift the flywheel cover off the engine.
a b a - Flywheel cover
b - Screws (3)
47585
2. Inspect the alternator drive belt.
a a - Alternator drive belt
47588
3. Replace the belt if any of the following conditions are found:
• Cracks in the back of the belt or in the base of the V grooves.
• Excessive wear at the roots of the grooves.
• Rubber portion swollen by oil.
• Belt surfaces roughened.
• Signs of wear on edges or outer surfaces of belt.
90-8M0060785 DECEMBER 2011 Page 1B-11

Maintenance
IMPORTANT: The alternator belt is a stretch to fit type belt that does not require an idler pulley to maintain belt
tension. If any of the following belt conditions are found, the belt must be replaced.
4. Install the flywheel cover and secure with three screws. Tighten the screws to the specified torque.

Flywheel cover screws 8 70.8
Alternator Belt Failure Identification

Appearance Description Cause Solution
Abrasion Replace the belt and

Belt is in contact with an object.
Each side of the belt appears inspect for contact object.
Can be caused by improper belt
shiny or glazed. Severe Verify the belt tensioner is
tension or tensioner failure.
condition: Fabric is exposed. functioning.
40791
Pilling There are a number of causes When pilling leads to belt

Belt material is sheared off from including lack of tension, noise or excess vibration,
the ribs and builds up in the belt misalignment, worn pulleys, or a the belt should be
grooves. combination of these factors. replaced.
40794
The belt life has been

severely limited and
Improper belt installation is a should be replaced
Improper install
common cause of premature immediately. Ensure all
The belt ribs begin separating
failure. One of the outermost belt ribs of the replacement
from the joined strands. If left
ribs is placed outside the pulley belt fit into the pulley
unattended, the cover will often
groove, causing a belt rib to run grooves. Run the engine.
separate, causing the belt to
without a supporting or aligning Then, with the engine off
unravel.
pulley groove. and battery disconnected,
40795 inspect the belt for proper
installation.
Misalignment
Sidewalls of the belt may appear
glazed or the edge‑cord may Pulley misalignment. Misalignment Replace the belt and
become frayed and the ribs are forces the belt to kink or twist while verify the alignment of the
removed. A noticeable noise running, causing premature wear. pulley.
may result. In severe cases, the
belt can jump off the pulley.
40796
Chunk‑out
Chunk‑out can happen when
Pieces or chunks of rubber
several cracks in one area move
material have broken off the Replace the belt
parallel to the cord line. Heat, age,
belt. When chunk‑out has immediately.
and stress are the primary
occurred, a belt can fail at any
contributors.
moment.
40797
Page 1B-12 90-8M0060785 DECEMBER 2011

Maintenance
Appearance Description Cause Solution
Uneven rib wear

Replace the belt and
Belt shows damage to the side A foreign object in the pulley can
inspect all pulleys for
with the possibility of breaks in cause uneven wear and cut into
foreign objects or
the tensile cord or jagged edged the belt.
damage.
ribs.
40799
Continuous exposure to high

temperatures, the stress of
bending around the pulley leads to
Cracking
cracking. Cracks begin on the ribs Replace the belt
Small visible cracks along the
and grow into the cord line. If three immediately.
length of a rib or ribs.
or more cracks appear in a
three‑inch section of a belt, eighty
40800
percent of the life is gone.
Alternator Belt Replacement

1. Loosen the front alternator bolt.
2. Remove the rear alternator bolt.
b a - Loosen
b - Remove
a
48145
3. Push the alternator towards the front of the engine.
48146
90-8M0060785 DECEMBER 2011 Page 1B-13

Maintenance
4. Remove the alternator belt.
48138
5. Install the alternator belt so the letters and numbers on the belt are legible.
48141
6. Push the alternator towards the rear of the engine.
48147
7. Install the rear alternator bolt and tighten to the specified torque.
Page 1B-14 90-8M0060785 DECEMBER 2011

Maintenance
8. Tighten the front alternator bolt to the specified torque.
b a - Front alternator bolt

b - Rear alternator bolt
a
48145

Alternator bolts (M10 x 60) 50 36.8
Lubrication Points
1. Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE.

95 2-4-C with PTFE Propeller shaft 92-802859A 1
• 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.
47623
2. Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with PTFE or Special Lubricant 101.

95 2-4-C with PTFE Steering cable 92-802859A 1
34 Special Lubricant 101 Steering cable 92-802865Q02
90-8M0060785 DECEMBER 2011 Page 1B-15

Maintenance
• Steering cable grease fitting (if equipped) ‑ Rotate steering wheel to fully retract the steering cable end into the
outboard tilt tube. Lubricate through fitting.
a b a - Fitting
b - Steering cable end
47651
! WARNING
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.
3. Lubricate the following with lightweight oil.
• Steering link rod pivot points ‑ Lubricate pivot points.
47652
Checking Power Trim Fluid

1. Tilt the outboard to the full up position and engage the tilt support lever.
47646
2. Remove the 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 and Steering Fluid. If not available, use automotive automatic transmission fluid
(ATF).
Page 1B-16 90-8M0060785 DECEMBER 2011

Maintenance

Power Trim and Steering
114 Power trim reservoir 92-858074K01
Fluid
47647
Checking and Adding Engine Oil

IMPORTANT: Do not overfill. Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to drain back to
the oil sump. Tilt outboard to vertical (not tilted) position when checking engine oil. For accurate readings, check oil only when
engine is cold or after engine has not run for at least an hour.
1. Before starting (cold engine) tilt outboard out/up past vertical to allow trapped oil to drain back to the oil sump. Allow
outboard to remain tilted for approximately one minute.
2. Tilt outboard to vertical operating position.
3. Remove the top cowl.
4. Pull out the dipstick. Wipe the dipstick end with a clean rag or towel and push it back in all the way.
5. Pull the dipstick back out again and observe the oil level. Oil should be in the operating range (between the top bar and
bottom bar).
IMPORTANT: Do not try to fill the oil level to the top bar. Oil level is correct as long as it appears in the operating range
(between the top bar and bottom bar).
b a- Oil level operating range

b- Top bar
c- Bottom bar
d d- Upper 1/3 level
c
47403
6. If the oil level is below the bottom bar, remove the oil filler cap and add approximately 500 ml (16 oz) of the specified
outboard motor oil. Allow a few minutes for the oil to drain to the oil sump and recheck the dipstick. If necessary, add
additional oil to bring the oil level within the upper 1/3 level of the operating range. Avoid overfilling, do not try to fill the oil
level to the top bar.
47404
90-8M0060785 DECEMBER 2011 Page 1B-17

Maintenance
IMPORTANT: Inspect oil for signs of contamination. Oil contaminated with water will have a milky color to it; oil
contaminated with fuel will have a strong fuel smell. If contaminated oil is noticed, have the engine checked by your dealer.
7. Push the dipstick back in all the way.
8. Install the oil fill cap hand‑tight.
9. Install the top cowl.
Changing Engine Oil

Engine Oil Capacity
Engine oil capacity is approximately 6 liter (6.3 US qt).
IMPORTANT: Tilt the outboard out/up past vertical for approximately one minute to allow any trapped oil to drain back to the oil
sump.
Oil Changing Procedure

1. Tilt the outboard out/up past vertical for approximately one minute to allow any trapped oil to drain back to the oil sump.
2. Tilt the outboard to a vertical position.
3. Use a 16 mm (5/8 in.) wrench and loosen the oil drain valve so that it can be turned by hand. Be careful not to open the
valve too far allowing oil to drain.
4. Attach a 12 mm (7/16 in.) I.D. drain hose to the oil drain valve. Position the opposite end of the hose into an appropriate
container.
5. Loosen the oil drain valve 2‑1/2 turns to allow oil to drain. Do not exceed 2‑1/2 turns.
IMPORTANT: Do not loosen the oil drain valve more than 2‑1/2 turns out. The oil seal could get damaged beyond 2‑1/2
turns.
6. After the oil has drained, hand‑tighten the oil drain valve (clockwise) and remove the oil drain hose.
7. Tighten the oil drain valve securely and clean any oil from the valve area.
a a - Oil drain valve

b - Drain hose
c - Loosen 2‑1/2 turns maximum
2-12
b
c
48870
Changing Oil Filter

1. Remove the plug from the oil trough and attach a 12 mm (7/16 in.) I.D. drain hose to the fitting. Position the opposite end of
the hose into an appropriate container.
2. Unscrew the old filter by turning the filter to the left.
3. Allow oil in the trough to drain and remove the oil drain hose.
4. Clean any oil from the oil trough and install the plug.
Page 1B-18 90-8M0060785 DECEMBER 2011

Maintenance
5. Clean the oil filter mounting base. Apply a film of clean oil to the filter gasket. Do not use grease. Screw new filter on until
gasket contacts base, then tighten 3/4 to 1 turn.
a a- Loosen
b- Oil filter
c- Oil trough
d- Drain hose
b
c
d
47562
Oil Filling
1. Remove the oil fill cap and add approximately 6 liters (6.3 US qt) of the recommended oil. This will bring the oil level within
the midpoint of the operating range.
2. Idle engine for five minutes and check for leaks. Stop the engine. For an accurate oil level reading, allow the engine to cool
for at least an hour before checking the oil level.
NOTE: Checking the oil level within five minutes of engine shutdown can falsely read up to 1 liter (1 US qt) low. Allow the
engine to cool for at least an hour before checking the oil level.
47404
Gearcase Lubrication
Gearcase Lubricant Capacity
Gearcase Lubricant Capacity (approximate)
Right‑hand rotation gearcase 780 ml (26.4 fl oz)
Left‑hand rotation gearcase 545 ml (18.4 fl oz)
When adding or changing gearcase lubricant, visually check for the presence of water in the lubricant. If water is present, it may
have settled to the bottom and will drain out prior to the lubricant, or it may be mixed with the lubricant, giving it a milky colored
appearance. If water is noticed, have the gearcase checked by your dealer. Water in the lubricant may result in premature
bearing failure or, in freezing temperatures, will turn to ice and damage the gearcase.
Examine the drained gearcase lubricant for metal particles. A small amount of metal particles indicates normal gear wear. An
excessive amount of metal filings or larger particles (chips) may indicate abnormal gear wear and should be checked by an
authorized dealer.
Draining Gearcase
1. Place outboard in a vertical operating position.
2. Remove propeller. Refer to Propeller Replacement.
3. Place drain pan below outboard.
90-8M0060785 DECEMBER 2011 Page 1B-19

Maintenance
4. Remove vent plug and fill/drain plug and drain lubricant.
a - Vent plug
b - Fill/drain plug
b
a
22692
Gearcase Lubricant Recommendation

Mercury or Quicksilver High Performance Gear Lubricant.
Checking Lubricant Level and Refilling Gearcase

1. Place outboard in a vertical operating position.
2. Remove vent plug/sealing washer.
3. Remove fill/drain plug. Place lubricant tube into the fill hole and add lubricant until it appears at the vent hole.
a - Vent hole
b - Fill hole
a
22693
IMPORTANT: Replace sealing washers if damaged.

4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube.
5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.
Submerged Outboard
A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the
water. This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize
internal corrosion damage to the engine.
Page 1B-20 90-8M0060785 DECEMBER 2011

General Information
1
Section 1C - General Information C
Table of Contents
Powerhead Components................................................... 1C-3 Fuel and Oil..................................................................... 1C-10
Front View.................................................................. 1C-3 Fuel Recommendations............................................1C-10
Port View.................................................................... 1C-4 Filling Fuel Tank....................................................... 1C-10
Aft View...................................................................... 1C-5 Engine Oil Recommendations.................................. 1C-11
Starboard View........................................................... 1C-6 Compression Check........................................................ 1C-11
Top View.....................................................................1C-7 Cylinder Leakage Testing................................................ 1C-12
Conditions Affecting Performance..................................... 1C-7 Analysis.................................................................... 1C-12
Weather...................................................................... 1C-7 Painting Procedures........................................................ 1C-12
Weight Distribution (Passengers and Gear) Inside the Propellers................................................................. 1C-12
Boat.........................................................................1C-8 Gear Housing........................................................... 1C-13
Bottom of Boat ...........................................................1C-8 Decal Removal................................................................ 1C-13
Water Absorption........................................................1C-8 Decal Application............................................................. 1C-13
Cavitation....................................................................1C-8 Shipping of Hazardous Material (HazMat) and Engine/
Ventilation...................................................................1C-8 Components Containing Hazardous Material.............. 1C-14
Detonation.................................................................. 1C-9 Outboard Service Bulletin 2008‑07...........................1C-14
Following Complete Engine Submersion ..........................1C-9 Overview of Regulations...........................................1C-14
Engine Submerged While Running (Special Overview of Training Requirements......................... 1C-14
Instructions)............................................................ 1C-9 Shipping of Complete Engines and Major Assemblies
Fresh Water Submersion (Special Instructions)......... 1C-9 .............................................................................. 1C-14
Saltwater Submersion (Special Instructions)..............1C-9 More Information on Hazardous Material................. 1C-14
90-8M0060785 DECEMBER 2011 Page 1C-1

General Information
Special Tools
Compression Tester with Adapter Snap‑On EEPV303B
Checks cylinder compression. Use with M14 x 1.25 adapter.
8511
Cylinder Leakage Tester Snap‑On EEPV309A
Aids in checking cylinder leakdown.
11604
Page 1C-2 90-8M0060785 DECEMBER 2011

General Information
Powerhead Components
Front View
1- Trim motor wire harness

9 2- Battery cables
3- Speedometer hose
4- Fuel in‑line
10 5- ECM
6- Oil filter
7- Dipstick
8- Starter
8 9- Oil fill cap
10 - Fuses
11 - Electrical cover
11 12 - Engine harness connector
13 - Termination resistor
(diagnostic port)
14 - Fresh water flush hose
12
15 - Trim motor engine harness
connectors
16 - Trim position sender wire
13
harness
7
14
15
3 16
1 48075
90-8M0060785 DECEMBER 2011 Page 1C-3

General Information
Port View
12 1- Engine harness cowl
11 13
trim switch connector
14 2- Digital speedometer
15 connector (optional)
3- Fresh water flush
hose
4- Trim motor engine
10 harness connectors
5- Trim position sender
9 wire harness
connector
16
6- PCM harness
connector
7- Termination resistor
8 (diagnostic port)
8- Engine harness
connector
7
9- Electrical cover
10 - Fuses
17 11 - Oil fill cap
6
12 - Ignition coil (1 and 4)
18 13 - Alternator
5 14 - Exhaust manifold
4 15 - Spark plug wire
16 - Water pressure
sensor port (optional)
17 - Ignition coil (2 and 3)
18 - Water hose going to
FSM
19 - Muffler
19
48076
3 2 1
Page 1C-4 90-8M0060785 DECEMBER 2011

General Information
Aft View
4 1- Fuel supply module (FSM)

5 2- Muffler
3- Spark plug wire
6
4- Water pump indicator hose
5- Crankcase ventilation hose
7 6- Throttle lever
8 7- Fuel rail
8- Intake manifold
9- Fuel injector
9 10 - Manifold air temperature sensor (MAT)
11 - Throttle lever
12 - Water pump indicator hose
13 - High‑pressure fuel filter
10
11
3
12
13
2
48107
90-8M0060785 DECEMBER 2011 Page 1C-5

General Information
Starboard View
16 1- Fuel supply module

15 fuel cooler water
14 dump
17
13 2- Oil drain valve
3- Fuel supply module
fuel supply hose
18 4- Fuel supply filter
(low pressure)
12 5- Water pump
19 indicator
6- Throttle lever
20
7- Muffler
21 8- High‑pressure fuel
22 filter
11 9- Cylinder block water
23 dump
24 10 - Manifold air
temperature (MAT)
sensor
10 25 11 - Dipstick
12 - Fuel rail
9 26
13 - Crankcase
ventilation hose
8 14 - Throttle link
15 - Throttle body
7 16 - Throttle position
27 sensor (TPS)
17 - Starter
18 - Oil pressure switch
19 - Manifold air
pressure (MAP)
6
sensor
5 20 - Idle air control (IAC)
21 - Oil filter
4
22 - Diagnostic port
3 23 - Vessel sensor
harness connector
24 - PCM harness
2 28 connector
25 - Battery cables
26 - Shift position switch
1 (hidden)
48108
27 - Fuel supply hose
28 - Speedometer hose
Page 1C-6 90-8M0060785 DECEMBER 2011

General Information
Top View
7 1- Flywheel
2- Starter
3- Throttle position sensor
8 (TPS)
6 4- Throttle body screen
9 5- Throttle link
6- Crankcase ventilation
5 hose
7- Hose to water pump
indicator
10 8- Cylinder block
temperature sensor
9- Thermostat housing
4 10 - Alternator
11 - Crankshaft position
sensor (CPS)
12 - Fuse holder
3 13 - Oil fill cap
11
1 12
13 48109
Conditions Affecting Performance

Weather
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.
Corporations internationally have settled on adoption of International Standards Organization (ISO) engine test standards, as
set forth in ISO 3046 standardizing the computation of horsepower from data obtained on the dynamometer. All values are
corrected to the power the engine will produce at sea level, at 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.
This, in turn, is reflected in decreased boat speeds as much as 3 to 5 km/h (2 to 3 MPH) in some cases. Nothing will regain this
speed for the boater but cooler, dry weather.
90-8M0060785 DECEMBER 2011 Page 1C-7

General Information
Pointing out the consequences of weather effects, an engine running on a hot, humid day may encounter a loss of as much as
14% of the horsepower it would produce on a dry, brisk day. The horsepower that any internal combustion engine produces,
depends upon the density of the air that it consumes. The density of air is dependent upon the ambient air temperature, the
barometric pressure, and the humidity (water vapor) content.
Accompanying the effects of weather inspired loss of power is a second, but more subtle loss. Consider a boat rigged during
cooler, less humid weather with a propeller that allowed the engine to turn within its recommended RPM range at full throttle.
Higher temperatures with high humidity weather will consequently decrease the available horsepower. The propeller, in effect,
is too large for the atmospheric conditions and the engine operates at less than its recommended RPM.
The engine rated horsepower is a direct relation to the engines' RPM. An engine with too large a propeller will have a further
loss of horsepower and subsequent decrease in boat speed. This secondary loss of RPM and boat speed can be regained by
switching to a smaller pitch propeller that allows the engine to run at recommended RPM.
For boaters to realize optimum engine performance under changing weather conditions, it is essential the engine has the
proper propeller to allow it to operate at, or near, the top end of the recommended maximum RPM range at wide‑open throttle
with a normal boat load. Not only does this allow the engine to develop full power, but equally important, the engine will be
operating in an RPM range that discourages damaging detonation. This enhances overall reliability and durability of the engine.
Weight Distribution (Passengers and Gear) Inside the Boat

Shifting weight to rear (stern):
• Generally increases speed and engine RPM
• Causes bow to bounce in choppy water
• Increases danger of following wave splashing into the boat when coming off plane
• At extremes, can cause the boat to porpoise
Shifting weight to front (bow):
• Improves ease of planing
• Improves rough water ride
• At extremes, can cause the boat to veer back and forth (bow steer)
Bottom of Boat
For maximum speed, a boat bottom should be nearly a flat plane where it contacts the water and particularly straight and
smooth in fore and aft direction.
• Hook: Exists when bottom is concave in fore and aft direction when viewed from the side. When boat is planing, hook
causes more lift on bottom near transom and allows bow to drop, thus greatly increasing wetted surface and reducing boat
speed. Hook frequently is caused by supporting boat too far ahead of transom while hauling on a trailer or during storage.
• Rocker: The reverse of hook and much less common. Rocker exists if bottom is convex in fore and aft direction when
viewed from the side, and boat has strong tendency to porpoise.
• Surface roughness: Moss, barnacles, etc., on boat or corrosion of outboard's gear housing increase skin friction and
cause speed loss. Clean surfaces when necessary.
Water Absorption
It is imperative that all through‑the‑hull fasteners be coated with a quality marine sealer at time of installation. Water intrusion
into the transom core and/or inner hull will result in additional boat weight (reduced boat performance), hull decay, and eventual
structural failure.
Cavitation
Cavitation occurs when water flow cannot follow the contour of a fast‑moving underwater object, such as a gear housing or a
propeller. Cavitation increases propeller speed while reducing boat speed. Cavitation can seriously erode the surface of the
gear housing or the propeller. Common causes of cavitation are:
• Weeds or other debris snagged on the propeller
• Bent propeller blade
• Raised burrs or sharp edges on the propeller
Ventilation
Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speed‑up
and a reduction in boat speed. Air bubbles strike the propeller blade and cause erosion of the blade surface. If allowed to
continue, eventual blade failure (breakage) will occur. Excessive ventilation is usually caused by:
• Drive unit trimmed out too far
• A missing propeller diffuser ring
Page 1C-8 90-8M0060785 DECEMBER 2011

General Information
• A damaged propeller or gear housing, which allows exhaust gases to escape between propeller and gear housing
• Drive unit installed too high on transom
Detonation
Detonation in a 4‑cycle engine resembles the pinging heard in an automobile engine. It can be otherwise described as a tin‑like
rattling or plinking sound.
Detonation is the explosion of the unburned fuel/air charge after the spark plug has fired. Detonation creates severe shock
waves in the engine. These shock waves often find or create a weakness: the dome of a piston, cylinder head or gasket, piston
rings or piston ring lands, piston pin, and roller bearings.
A few of the most common causes of detonation in a marine 4‑cycle application are as follows:
• Over‑advanced ignition timing
• Use of low octane gasoline
• Propeller pitch too high: engine RPM below recommended maximum range
• Lean fuel mixture at, or near, wide‑open throttle
• Spark plugs: heat range too hot, incorrect reach, cross‑firing
• Deteriorated or inadequate engine cooling system
• Combustion chamber deposits: result in higher compression ratio
Detonation usually can be prevented if:
• The engine is correctly set up
• Regular maintenance is scheduled
Following Complete Engine Submersion

Engine Submerged While Running (Special Instructions)
When an engine is submerged while running, the possibility of internal engine damage is greatly increased. After the engine is
recovered, remove the spark plugs. If the engine fails to turn over freely when turning the flywheel, the possibility of internal
damage (bent connecting rod and/or bent crankshaft) exists. The powerhead must be disassembled for inspection.
Fresh Water Submersion (Special Instructions)

1. Recover the engine as quickly as possible.
2. Place engine at full trim in.
3. Remove the cowling.
4. Flush the exterior of the outboard with fresh water to remove mud, weeds, etc. Do not attempt to start the engine if sand
has entered the powerhead. Disassemble the powerhead, if necessary, to clean components.
5. Remove the spark plugs and get as much water as possible out of the powerhead. Most of the water inside the combustion
chambers can be eliminated by rotating the flywheel while the engine is trimmed all the way in.
6. Remove and clean the fuel rail, fuel supply module, idle air control, throttle body, and fuel pump assembly.
7. Pour approximately one teaspoon of engine oil into each spark plug opening. Rotate the flywheel to distribute the oil in the
cylinders.
8. Drain and replace the engine oil.
9. Dry all wiring and electrical components using compressed air.
10. Replace the starter motor if required.
11. Install the spark plugs.
12. Attempt to start engine with a fresh fuel source. If the engine starts, it should be run for at least one hour to eliminate any
water in engine. Run the outboard for at least one hour and check for the presence of water in the oil. If water is present,
the oil will appear milky. Drain and replace the oil as previously mentioned.
13. If the engine fails to start, determine if the cause is fuel related, electrical, or mechanical. The engine should be run within
two hours after recovery from the water, or serious internal damage will occur. If the engine is unable to start within two
hours of recovery, disassemble the engine and clean all parts. Apply oil as soon as possible.
Saltwater Submersion (Special Instructions)

Due to the corrosive effect of saltwater on internal engine components, complete disassembly of the engine is necessary
before any attempt is made to start the engine.
90-8M0060785 DECEMBER 2011 Page 1C-9

General Information
Fuel and Oil

Fuel Recommendations
IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper
gasoline is considered misuse of the engine, and damage caused thereby will not be covered under the limited
warranty.
Fuel Ratings
Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following
specifications:
USA and Canada ‑ having a posted pump Octane Rating of 87 (R+M)/2 minimum. Premium gasoline [92 (R+M)/2 Octane] is
also acceptable. Do not use leaded gasoline.
Outside USA and Canada ‑ having a posted pump Octane Rating of 90 RON minimum. Premium gasoline (98 RON) is also
acceptable. Do not use leaded gasoline.
Using Reformulated (Oxygenated) Gasolines (USA Only)

This type of gasoline is required in certain areas of the USA. The 2 types of oxygenates used in these fuels are Alcohol
(Ethanol) or Ether (MTBE or ETBE). If Ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasolines
Containing Alcohol.
These Reformulated Gasolines are acceptable for use in your Mercury Marine engine.
Gasolines Containing Alcohol

If the gasoline in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), you should be aware of certain
adverse effects that can occur. These adverse effects are more severe with methanol. Increasing the percentage of alcohol in
the fuel can also worsen these adverse effects.
Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air, which can
result in a separation of the water/alcohol from the gasoline in the fuel tank.
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). Be aware that gasolines containing alcohol may
cause increased:
• Corrosion of metal parts
• Deterioration of rubber or plastic parts
• Fuel permeation through rubber fuel lines
• Starting and operating difficulties
! WARNING
Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system
components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or
deterioration requires replacement before further engine operation.
Because of possible adverse effects of alcohol in gasoline, it is recommended that only alcohol‑free gasoline be used where
possible. If only fuel containing alcohol is available, or if the presence of alcohol is unknown, increased inspection frequency for
leaks and abnormalities is required.
IMPORTANT: When operating a Mercury Marine engine on gasoline containing alcohol, storage of gasoline in the fuel tank for
long periods should be avoided. Long periods of storage, common to boats, create unique problems. In cars, alcohol‑blend
fuels normally are consumed before they can absorb enough moisture to cause trouble, but boats often sit idle long enough for
phase separation to take place. In addition, internal corrosion may take place during storage if alcohol has washed protective
oil films from internal components.
Filling Fuel Tank

! WARNING
Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. Always stop the engine and
do not smoke or allow open flames or sparks in the area while filling fuel tanks.
Fill fuel tanks outdoors away from heat, sparks, and open flames.
Remove portable fuel tanks from boat to refill them.
Always stop engine before refilling tanks.
Page 1C-10 90-8M0060785 DECEMBER 2011

General Information
Do not completely fill the fuel tanks. Leave approximately 10% of the tank volume unfilled. Fuel will expand in volume as its
temperature rises and can leak under pressure if the tank is completely filled.
Portable Fuel Tank Placement in the Boat

Place the fuel tank in the boat so the vent is higher than the fuel level under normal boat operating conditions.
Engine Oil Recommendations

Mercury or Quicksilver NMMA FC‑W certified synthetic blend 25W‑40 multi‑viscosity 4‑Stroke Outboard Oil is recommended for
commercial, and general, all‑temperature use. As an optional choice, Mercury or Quicksilver NMMA FC‑W certified 10W‑30
multi‑viscosity 4‑Stroke Outboard Oil may be used for boating where optimum acceleration performance is desired like water
skiing or tournament fishing. If the recommended Mercury or Quicksilver NMMA FC‑W certified oils are not available, a major
brand of NMMA FC‑W certified 4‑Stroke Outboard Oil of similar viscosity may be used.
IMPORTANT: The use of nondetergent 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.
Engine Oil
25W-40 FC-W
10W-30 FC-W
6.0L (6.3 U.S. qt.)
+120 +49
+100 +38
+80 +27
+60 +16
25W-40
10W-30
+40 +4
+20 -7
0 -18
F C
47814
Compression Check
Engine compression should be checked with the engine block at operating temperatures, all spark plugs removed, and using a
fully charged battery.
1. Remove spark plugs.
2. Install compression gauge in spark plug hole.
a - Compression gauge
a b - 14 mm adapter
5525
Compression Tester with Adapter Snap‑On EEPV303B

3. Crank the engine over until the compression reading peaks on the gauge. Record the reading.
4. Check and record compression of each cylinder. The highest and lowest reading recorded should not differ by more than
15%. A reading below 827.4 kPa (120 psi) may indicate a total engine wear problem. The following example chart
below, is not a representation of compression values specific to the engine that is actually tested. It is only an
example.
Compression Test Differences

Condition Maximum Reading Minimum Reading
Good 1241 kPa (180 psi) 1062 kPa (154 psi)
Bad 1172 kPa (170 psi) 972.2 kPa (141 psi)
90-8M0060785 DECEMBER 2011 Page 1C-11

General Information
5. To find the maximum allowable minimum compression reading difference, use this formula; highest compression reading x
0.85 = the lowest allowable difference. 1241 kPa x 0.85 = 1054.85 kPa (180 x 0.85 = 153 psi).
6. Compression check is important because an engine with low or uneven compression cannot be tuned successfully to give
peak performance. It is essential therefore, that improper compression be corrected before proceeding with an engine
tune‑up.
7. A variance of more than 103.4 kPa (15 psi) indicates the need for a powerhead inspection/disassembly.
Cylinder Leakage Testing

Engine Firing Order
Cylinder sequence 1‑3‑4‑2
NOTE: Cylinder leakage testing, along with compression testing, can help the mechanic pinpoint the source of a mechanical
failure by gauging the amount of leakage in an engine cylinder. Refer to the manufacturer's tester instructions for proper testing
procedures.
Cylinder Leakage Tester Snap‑On EEPV309A
1. Place a straight edge across the top of the flywheel and make a mark on the flywheel 180° from the stamped timing mark.
2. Remove the spark plugs from cylinders #2, #3, and #4.
3. Rotate the flywheel clockwise until resistance is felt.
4. Continue to rotate the flywheel until the stamped timing mark on the flywheel is aligned with the timing pointer. This will be
the compression stroke for cylinder #1.
5. Remove the spark plug from cylinder #1.
6. Complete the cylinder leak‑down test on the #1 spark plug hole. Refer to the manufacturer's tester instructions for proper
testing procedures.
7. Rotate the flywheel 180° clockwise until the 180° mark on the flywheel (made in step 1) is aligned with the timing pointer.
Complete the cylinder leak‑down test on the #3 spark plug hole.
8. Rotate the flywheel clockwise another 180° until the stamped timing mark on the flywheel is aligned with the timing pointer.
Complete the cylinder leak‑down test on the #4 spark plug hole.
9. Rotate the flywheel 180° clockwise until the 180° mark on the flywheel is aligned with the timing pointer. Complete the
cylinder leak‑down test on the #2 spark plug hole.
Analysis
Due to standard engine tolerances and engine wear, no cylinder will maintain a 0% of leakage. It is important only that cylinders
have somewhat consistent reading between them. Differences of 15 to 30% indicate excessive leakage. Larger engines tend to
have a larger percentage of cylinder leakage than smaller engines.
If excessive leakage is present, first check that the piston is at top dead center of its compression stroke. Leakage will naturally
occur if the exhaust or intake valve is open.
To determine the cause of high percentage leaks, you must locate where the air is escaping from. Listen for air escaping
through the intake, adjacent spark plug holes, exhaust pipe, and crankcase oil fill plug. Use the following table to aid in locating
the source of cylinder leakage.
Air Escaping from Possible Location

Air induction Intake valve
Exhaust system Exhaust valve
Oil fill plug Piston/rings
Adjacent cylinder Head gasket
Painting Procedures
! WARNING
Continuous exposure to airborne particles such as chemical vapors, dust, or spray can cause serious injury or death. Ensure
that the work area is properly ventilated and wear protective eyeware, clothing, and respirators.
Propellers
1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch‑Brite disc or belts.
Page 1C-12 90-8M0060785 DECEMBER 2011

General Information
2. Feather edges of all broken paint edges. Try not to sand through the primer.
3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or equivalent (Xylene or M.E.K.).
4. If bare metal has been exposed, use Mercury/Quicksilver Light Gray Primer.
5. Allow a minimum of one hour dry time and no more than one week before applying the finish coat.
6. Apply the finish coat using Mercury/Quicksilver EDP Propeller Black.
Gear Housing
The following procedures should be used in refinishing gear housings. This procedure will provide the most durable paint
system available in the field. The materials recommended are of high quality and approximate marine requirements. The
following procedure will provide a repaint job that compares with a properly applied factory paint finish. It is recommended the
listed materials be purchased from a local Ditzler Automotive Finish Supply Outlet. The minimum package quantity of each
material shown following is sufficient to refinish several gear housings.
1. Wash the gear housing with a muriatic acid base cleaner to remove any type of marine growth, and rinse with water.
2. Wash the gear housing with soap and water. Rinse with clean water.
3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only. Feather edge all
broken paint edges.
4. Clean gear housing thoroughly with DX‑330 Wax and Grease Remover.
5. Spot repair surfaces where bare metal is exposed with DX‑503 Alodine Treatment.
IMPORTANT: Do not use aerosol spray paints as the paint will not properly adhere to the surface, nor will the coating be
sufficiently thick to resist future paint blistering.
6. Mix Epoxy Chromate Primer DP‑90LF with equal part catalyst DP‑402LF per the manufacturer's instructions. Allow proper
induction period for permeation of the epoxy primer and catalyst.
7. Allow a minimum of one hour drying time and no more than one week before the top coat application.
8. Use Ditzler Urethane DU9300 for Mercury Black, DU34334 for Mariner Grey, DU35466 for Force Charcoal, DU33414M for
Sea Ray White, and DFHS 37372H for Verado Silver. Catalyze all five colors with Ditzler DU5 catalyst mixed 1:1 ratio.
Reduce with solvents per Ditzler label.
! WARNING
Continuous exposure to airborne particles such as chemical vapors, dust, or spray can cause serious injury or death. Ensure
that the work area is properly ventilated and wear protective eyeware, clothing, and respirators.
NOTE: Apply one half to one mil even film thickness with a spray gun. Allow the paint to flash off for five minutes before
applying the second even coat of one half to one mil film thickness. Urethane paint will dry to the touch in a matter of
hours, but will remain sensitive to scratches and abrasions for a few days.
9. The type of spray gun used will determine the proper reduction ratio of the paint.
IMPORTANT: Do not paint the sacrificial anode.
10. Cut out a cardboard plug for trim tab pocket to keep paint off of mating surface to maintain good continuity circuitry
between trim tab and gear housing.
Decal Removal
1. Mark decal location before removal to assure proper alignment of new decal.
2. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing old decal.
3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water.
4. Thoroughly dry decal contact area and check for a completely cleaned surface.
Decal Application
1. Mix 16 ml (1/2 oz) of dishwashing liquid in 4 liter (1 US gal) of cool water to use as a wetting solution.
NOTE: Leave protective masking on the face of the decal until final steps of decal installation. This will ensure the vinyl
decal keeps its shape during installation.
2. Place the decal face down on a clean work surface and remove the paper backing from adhesive side of decal.
3. Using a spray bottle, flood the entire adhesive side of the decal with the premixed wetting solution.
4. Flood area where the decal will be positioned with wetting solution.
5. Position prewetted decal on wetted surface and slide into position.
6. Starting at the center of the decal, lightly squeegee out the air bubbles and wetting solution with overlapping strokes to the
outer edge of the decal. Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl
surface.
90-8M0060785 DECEMBER 2011 Page 1C-13

General Information
7. Wipe decal surface with a soft paper towel or cloth.
8. Wait 10–15 minutes.
9. Starting at one corner, carefully and slowly pull the masking off the decal surface at a 180° angle.
NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with a stick pin and press out the
entrapped air or wetting solution with your thumb, moving toward the puncture.
Shipping of Hazardous Material (HazMat) and Engine/Components Containing

Hazardous Material
Outboard Service Bulletin 2008‑07
There are a number of United States regulations regarding the shipment of hazardous material. These regulations apply not
only to shipments within the United States, but to import and export shipments as well. It is important to comply with all of these
regulations. This bulletin is intended to provide you with some basic information about some of these regulations, and provide
you with information about resources from which you can obtain additional information. It is also intended to draw your attention
to the importance of proper packaging, labeling, and shipping of hazardous material; as well as any engine or engine
component that contains hazardous material like gasoline or other fluids such as crankcase oil, gearcase oil, and hydraulic
fluid. There are also requirements for training personnel that deal with the shipment of hazardous material. This bulletin is
intended to draw your attention to some of the shipping regulations that we are aware of that might apply to your business, it is
not a complete review of all of the laws and regulations that apply to the shipment of hazardous materials. Please do not treat it
as such.
NOTE: You, as the shipper of record, are responsible for classification, packaging, hazard communication, incident reporting,
handling, and transportation of hazardous materials.
Overview of Regulations
The Hazardous Materials Regulations (HMR) specify requirements for the safe transportation of hazardous materials in
commerce by rail car, aircraft, vessel, and motor vehicle. These comprehensive regulations govern transportation‑related
activities. In general, the HMR prescribe requirements for classification, packaging, hazard communication, incident reporting,
handling, and transportation of hazardous materials. The HMR are enforced by Pipeline Hazardous Material Safety
Administration (PHMSA), Department of Transportation (DOT), Federal Aviation Administration (FAA), Federal Highway
Administration (FHWA), Federal Railroad Administration (FRA), and the United States Coast Guard (USCG).
Overview of Training Requirements

Current U.S. Department of Transportation (DOT) regulations require initial training (and recurrent training) of all employees
who perform work functions covered by the Hazardous Materials Regulations. Any employee who works in a shipping,
receiving, or material handling area; or who may be involved in preparing or transporting hazardous materials, is required to
have training. Hazardous materials transportation training is available from ShipMate, Inc. The training modules on CD‑ROM or
online contain an interactive training program which satisfies the DOT requirement for general awareness, general safety, and
HazMat security training. A comprehensive exam is offered and Certificates of Completion are generated upon successful
completion of the program. The CD‑ROM and online Web‑Based Training may be purchased from ShipMate, Inc. This also
includes an electronic version of the 49 CFR Hazardous Materials Regulations, the current Emergency Response Guidebook,
and full access to ShipMate’s technical staff to assist you in properly preparing hazardous materials for transport. ShipMate,
Inc. may be reached at 1‑310‑370‑3600 or on the web at http://www.shipmate.com.
NOTE: The DOT training program does NOT include a test of any type and contains a lot of material which is not relevant (e.g.
cargo tanks). In addition, you would have to purchase the 49 CFR and the Emergency Response Guidebook separately.
Further, the DOT program provides no support – technical or otherwise. For further information, view the DOT website at http://
www.dot.gov.
Shipping of Complete Engines and Major Assemblies

Complete engines cannot be transported without going through additional preparation first. Electronic fuel injection (EFI) and
direct fuel injection (DFI) engines must have the fuel system drained of fuel, not run dry because of possible damage to electric
fuel pumps. Carbureted engines must be completely run dry and have stalled due to lack of fuel. All engines must have any
remaining fluids/oils drained (including engine and gearcase oil) and hydraulic fluids (including power trim fluid) and
disconnected fluid pipes that previously contained fluid must be sealed with leakproof caps that are positively retained. Major
assemblies such as gearcases, dressed powerheads, or other components containing any fluids must be also drained prior to
shipping.
More Information on Hazardous Material

More information on hazardous material, regulations, packaging, training, etc. can be found by going to the ShipMate website:
http://www.shipmate.com or by calling:
Page 1C-14 90-8M0060785 DECEMBER 2011

General Information
ShipMate Inc.
Telephone + 1 (310) 370‑3600
Fax + 1 (310) 370‑5700
E‑mail shipmate@shipmate.com
90-8M0060785 DECEMBER 2011 Page 1C-15

General Information
Notes:
Page 1C-16 90-8M0060785 DECEMBER 2011

Outboard Installation
1
Section 1D - Outboard Installation D
Table of Contents
Boat Horsepower Capacity................................................ 1D-2 EPA Pressurized Portable Fuel Tank Requirements
Start in Gear Protection..................................................... 1D-2 ................................................................................ 1D-7
Installation Specifications.................................................. 1D-3 Fuel Demand Valve (FDV) Requirement....................1D-8
Lifting Outboard................................................................. 1D-3 Fuel Tanks..................................................................1D-8
Steering Cable ‑ Starboard Side Routed Cable.................1D-3 Fuel Supply Module Priming Procedure..................... 1D-8
Steering Link Rod Fasteners (if equipped)........................ 1D-4 Electrical, Fuel Hose, and Control Cables......................... 1D-9
Determining Recommended Outboard Mounting Height Rigging Grommet....................................................... 1D-9
....................................................................................... 1D-5 Remote Wiring Harness........................................... 1D-11
Drilling Outboard Mounting Holes......................................1D-5 SmartCraft Harness and Vessel Harness Connection
Fastening the Outboard to the Transom............................1D-6 .............................................................................. 1D-11
Mounting Bolts............................................................1D-6 Battery Cable Connections.......................................1D-11
Checking Boat Transom Construction........................1D-6 Fuel Hose Connection.............................................. 1D-12
Fuel System.......................................................................1D-7 Shift Cable Installation..............................................1D-12
Avoiding Fuel Flow Restriction................................... 1D-7 Throttle Cable Installation.........................................1D-14
Low Permeation Fuel Hose Requirement ..................1D-7
90-8M0060785 DECEMBER 2011 Page 1D-1


95 2-4-C with PTFE O-ring seal and entire cable end 92-802859A 1
Special Tools
Flywheel Puller/Lifting Ring 91‑895343T02
Removes flywheel from engine. Used for lifting powerhead/engine.

14869
Transom Drilling Fixture 91‑98234A2
Aids in engine installation by acting as a template for engine mounting holes.
5489
Boat Horsepower Capacity

! WARNING
Exceeding the boat's maximum horsepower rating can cause serious injury or death. Overpowering the boat can affect boat
control and flotation characteristics or break the transom. Do not install an engine that exceeds the boat's maximum power
rating.
Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable
power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the
boat manufacturer.
U.S. COAST GUARD CAP ACITY

MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
26777
Start in Gear Protection

! WARNING
Starting the engine with the drive in gear can cause serious injury or death. Never operate a boat that does not have a
neutral‑safety‑protection device.
The remote control connected to the outboard must be equipped with a start in neutral only protection device. This prevents the
engine from starting in gear.
Page 1D-2 90-8M0060785 DECEMBER 2011

Installation Specifications
a
a - Minimum transom opening
a b b - Engine centerline for dual engine ‑ 66.0 cm
(26 in.)
18552
Minimum Transom Opening

Single engine 84.2 cm (33 in.)
Dual engine 149.9 cm (59 in.)
Lifting Outboard
2. Install the lifting base to the flywheel using three bolts. Tighten the bolts securely.
3. Thread the lifting eye into the lifting base.
4. Connect a hoist that has a minimum lift capacity of 450 kg (1000 lb) to the lifting eye.
5. Lift the outboard and place it on the transom.
b a - Lifting base
a
b - Lifting eye
47706
Steering Cable ‑ Starboard Side Routed Cable

1. Lubricate O‑ring seal and entire cable end.
95
3724

95 2-4-C with PTFE O-ring seal and entire cable end 92-802859A 1
2. Insert steering cable into tilt tube.
90-8M0060785 DECEMBER 2011 Page 1D-3

3. Tighten the nut to the specified torque.
47708

Nut 47.5 35
Steering Link Rod Fasteners (if equipped)

IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using a special washer
head bolt ("a" ‑ Part Number 10‑856680) and self‑locking nylon insert locknuts ("c" and "d" ‑ Part Number 11‑826709113).
These locknuts must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link
rod to disengage.
! WARNING
Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This
can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown
within or out of the boat. Always use required components and follow instructions and torque procedures.
a a- Special washer head bolt (10‑856680)

b b- Flat washers
c- Nylon insert locknut (11‑826709113)
c d- Nylon insert locknut (11‑826709113)
d 47709

Special washer head bolt 27 20
Nylon insert locknut "d" 27 20
Tighten until it seats, then back off 1/4
Nylon insert locknut "c"
turn
Assemble steering link rod to steering cable with two flat washers and nylon insert locknut. Tighten locknut until it seats, then
back nut off 1/4 turn.
Assemble steering link rod to engine with special washer head bolt and locknut. First torque special washer head bolt, then
torque locknut to specifications.
Page 1D-4 90-8M0060785 DECEMBER 2011

Determining Recommended Outboard Mounting Height

63.5 cm
(25 in.)
a - The solid line is recommended to
60.9 cm
(24 in.) determine the outboard mounting height
e c b b - The broken lines represent the extremes
58.4 cm
(23 in.) of known successful outboard mounting
height dimensions
56.0 cm
(22 in.) c - This line may be preferred to determine
a outboard mounting height dimension, if
53.3 cm
(21 in.) maximum speed is the only objective
d - This line may be preferred to determine
50.8 cm
(20 in.) outboard mounting height dimension for
d dual outboard installation
e 48.2 cm
(19 in.) e - Outboard mounting height (height of
outboard mounting brackets from bottom
10 20 30 40 50 60 70 80 of boat transom). For heights over
56.0 cm (22 in.), a propeller that is
f 47710 designed for surfacing operation is
usually preferred.
f - 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. Having the exhaust relief hole above the waterline will
prevent exhaust restrictions. Exhaust restrictions will result in poor performance at idle.
2. Add 12.7 cm (5 in.) for XL models to the listed outboard mounting heights.
3. The mounting height of the outboard must not exceed 63.5 cm (25 in.) for L models, 76 cm (30 in.) for XL models.
Mounting the outboard higher may cause damage to the gearcase components.
Increasing the mounting height will usually:

• Reduce steering torque
• Increase top speed
• Increase boat stability
• Cause propeller to break loose during planing
Drilling Outboard Mounting Holes

IMPORTANT: Before drilling any mounting holes, carefully read Determining Recommended Outboard Mounting Height and
install outboard to the nearest recommended mounting height.
1. Mark four mounting holes on the transom using the transom drilling fixture.
b a - Drill guide holes

b - Transom drilling fixture
c - Transom centerline
c 2757
Transom Drilling Fixture 91‑98234A2
90-8M0060785 DECEMBER 2011 Page 1D-5

2. 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
10‑67755‑1 Outboard mounting bolt ½‑20 x 4.50 in. long (2.25 in. thread)
11‑826711‑17 Nylon insert locknut ½‑20
12‑28421 Flat washer 1‑1/2 in. diameter
12‑54012 Flat washer 7/8 in. diameter
Available Outboard Mounting Bolts

Part Number Description
10‑67755005 ½‑20 x 2.50 in. long (1.25 in. thread)
10‑67755‑1 ½‑20 x 4.50 in. long (2.25 in. thread)
10‑8M0033366 ½‑20 x 5.00 in. long (3.25 in. thread)
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. The boat transom must be strengthened or the load carrying area
increased.
a - Transom yielding under bolt torque

b - Transom cracking under bolt torque
b 18961
Page 1D-6 90-8M0060785 DECEMBER 2011

Use a dial torque wrench to determine transom strength. If the bolt or nut continues to turn without the torque reading on the
dial increasing, it is an indication that the transom is yielding. The load area can be increased by using a larger washer or a
transom reinforcement plate.
a
a - Large transom washer
b - Transom reinforcement plate
b
33962
1. Apply marine sealer to the shanks of the bolts, not to the threads.
2. Fasten the outboard with the correct mounting hardware. Tighten the locknuts to the specified torque.
IMPORTANT: Ensure a minimum of two full threads of the mounting bolts extend beyond the locknut after tightening. The
locknut must be drawn tight while still engaging the bolt threads and not contacting the shank of the bolt.
NOTE: For more accurate torque, tighten the mounting locknuts rather than the outboard mounting bolts.
a- 1/2 in. diameter outboard mounting bolt (4)

d
b- 7/8 in. flat washer (4)
c c- Nylon insert locknut (4)
a
d- 1‑1/2 in. flat washer (4)
e- Marine sealer ‑ apply to the shank of the
bolts, not the threads
e
b
c
d a
47373

Fuel System
Avoiding Fuel Flow Restriction
IMPORTANT: Adding components to the fuel supply system (filters, valves, fittings, etc.) may restrict the fuel flow. This may
cause engine stalling at low speed, and/or a lean fuel condition at high RPM that could cause engine damage.
Low Permeation Fuel Hose Requirement

Required for outboards manufactured for sale, sold, or offered for sale in the United States.
• The Environmental Protection Agency (EPA) requires that any outboard manufactured after January 1, 2009 must use low
permeation fuel hose for the primary fuel hose connecting the fuel tank to the outboard.
• Low permeation hose is USCG Type B1‑15 or Type A1‑15, defined as not exceeding 15/gm²/24 h with CE 10 fuel at 23 °C
as specified in SAE J 1527 ‑ marine fuel hose.
EPA Pressurized Portable Fuel Tank Requirements

The Environmental Protection Agency (EPA) will require portable fuel systems that are produced after January 1, 2011 for use
with outboard engines to remain fully sealed (pressurized) up to 34.4 kPa (5.0 psi). These tanks may contain the following:
90-8M0060785 DECEMBER 2011 Page 1D-7

• An air inlet that opens to allow air to enter as the fuel is drawn out of the tank.
• An air outlet that opens (vents) to the atmosphere if pressure exceeds 34.4 kPa (5.0 psi).
Fuel Demand Valve (FDV) Requirement

Whenever a pressurized fuel tank is used, a fuel demand valve is required to be installed in the fuel hose between the fuel tank
and the engine. The fuel demand valve prevents pressurized fuel from entering the engine and causing a fuel system overflow
or possible fuel spillage.
The fuel demand valve has a manual release. The manual release can be used (pushed in) to open (bypass) the valve in case
of a fuel blockage in the valve.
b a - Fuel demand valve ‑ installed in the fuel hose between the fuel tank and the
a engine
b - Manual release
c - Vent/water drain holes
c 46273
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.
Fuel Supply Module Priming Procedure

The fuel supply module (FSM) is not vented to the ambient air. The air trapped in the FSM, fuel lines, and fuel rail, will be
slightly compressed during the initial ignition key "ON" with a dry or drained fuel system. Additional key "ON" events under
these conditions, will not compress the air further to finish the priming of the FSM. Excessive number of key "ON" events may
eventually damage the fuel pumps. The volume of air trapped in the FSM must be purged to prime the fuel system. This can be
achieved by connecting a tool to the fuel rail Schrader valve fitting to quickly purge the system into an approved container, or by
cranking the engine.
Priming the FSM with a Purge Tool

The use of a purge tool for priming the FSM is the preferred method, but is not always practical. The objective is to purge the
air entrained in the fuel system through a purge tool connected to the fuel rail Schrader valve test port. During the key "ON,"
opening the dump valve will allow the air to be purged from the FSM and fuel rail. This method should be used on vessels
where the fuel inlet system to the outboard is restrictive; anti‑siphon valve or holds a relatively large volume of fuel because of a
long fuel supply line or water separating fuel filter. If a primer bulb is installed, it can be used during the priming event to shorten
the amount of time required to start the engine.
1. Verify the engine is in a level vertical position.
2. Verify the vessel fuel supply line is connected to the outboard fuel system inlet fitting.
3. Connect a fuel pressure gauge to the fuel rail Schrader valve.
4. Secure the fuel pressure gauge purge hose into an appropriate fuel container to collect excess fuel.
5. Open the fuel pressure gauge purge valve and turn the ignition key "ON." The fuel pumps will run for approximately five
seconds.
6. Turn the ignition key "OFF" and then back "ON." The fuel pumps will run for approximately five seconds. Continue this
ignition key cycle until the purged fuel is relatively clear of air bubbles.
NOTE: If the outboard fuel system does not prime within 15 key "ON" events, check for leaks in the fuel supply line to the
outboard. Repair as needed. If no leak is found, the fuel supply system to the outboard may be too restrictive. Correct the
condition and try again.
7. Remove the fuel pressure gauge.
8. Turn the ignition key "ON." When the fuel pumps stop running, start the engine. The engine may not start on the first
attempt. The engine will run rough at idle for up to two minutes while the residual air is purged from the fuel system.
Page 1D-8 90-8M0060785 DECEMBER 2011

Priming the FSM (Ran out of Fuel Condition)

The use of a purge tool for priming the FSM is the preferred method, but is not always practical. When the vessel fuel system is
void of fuel volume, it can be primed without the use of a purge tool. The objective is to purge the air entrained in the fuel
system through the fuel injectors during engine cranking to allow fuel to enter the fuel module. This method can be used on
vessels where the fuel inlet system to the outboard is less restrictive and holds a relatively small volume of fuel; a short fuel
supply line, no water separating fuel filter, or water separating fuel filter is already primed. If a primer bulb is installed, it can be
used during the priming event to shorten the amount of time required to start the engine.
3. Turn the ignition key "ON." The fuel pumps will run for approximately five seconds.
4. Turn the ignition key to the "START" position and release the key. The ECM controls the activation of the starter. The
starter may continue cranking for up to eight seconds.
NOTE: When priming a drained fuel system, residual fuel may cause the engine to flare and stall which shortens the
engine cranking event.
5. Continue with the ignition key "ON" and "START" sequence until the engine continues to run.
IMPORTANT: Allow the starter motor to cool for 20 to 30 seconds between full eight second crank events. Limit the
number of events to a maximum of 10 full eight second cranking events.
6. Once the engine starts, it may run rough at idle for up to two minutes while the residual air is purged from the fuel system.
7. If the fuel system will not prime within 10 full eight second cranking events, use the previous procedure Priming the FSM
with a Purge Tool to prime the fuel system.
Electrical, Fuel Hose, and Control Cables

Rigging Grommet
Installation
IMPORTANT: Sufficient slack must exist in wiring harnesses, battery cables, and hoses, that are routed between the rigging
grommet and engine attachment points, to relieve stress and prevent hoses from being kinked or pinched.
90-8M0060785 DECEMBER 2011 Page 1D-9

1. Route the hoses, wiring, and cables through the rigging adapter and correct opening in the rigging grommet as shown.
a- Screw (2)
b- Rigging adapter
c- Rigging grommet
d- Speedometer tube
e- Remote 14 pin boat harness
f- Battery cable
g- Accessory harness
h- Shift cable
i- Fuel hose
d j- SmartCraft harness or additional harness
e
f k- Throttle cable
l- Accessory rigging grommet for use with
rigging tubes
k j
b
a i g
h
e
d
f
l
k
i j
g
h 48766
2. Fasten the rigging grommet and rigging adapter with two screws. Tighten the screws to the specified torque.
3. Hold the wiring, hoses, and cables together with a cable tie.
NOTICE
Inspect the position of the hose clamp located on the fuel hose to ensure that it will not chafe or cut into the adjacent wiring
harnesses.
a - Cable tie
47753

Screws for attaching the rigging adapter 6 53
Page 1D-10 90-8M0060785 DECEMBER 2011

Remote Wiring Harness

Route the remote 14 pin boat harness through the rigging grommet. Connect the remote harness to the 14 pin connector on the
engine harness. Fasten the harness with the retainer.
b c a - Remote 14 pin boat harness

b - Retainer
a c - 14 pin connector
47717
SmartCraft Harness and Vessel Harness Connection

If the boat is equipped with a SmartCraft and/or vessel (accessory) harness, route the wiring harness through the rigging
grommet and connect it to the connector on the engine.
a - Vessel (accessory) harness connector

a b - SmartCraft harness connector
47723
Battery Cable Connections

Single Outboard
a a - Red sleeve ‑ Positive (+)

b - Black sleeve ‑ Negative (–)
c - Cranking battery
(+)
b c
(-) 15496
90-8M0060785 DECEMBER 2011 Page 1D-11

Dual Outboards
Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting
batteries.
a a- Red sleeve ‑ Positive (+)

b- Black sleeve ‑ Negative (–)
c- Ground cable
d- Cranking battery
b
a (-)
d
b
c (-)
d
15497
Fuel Hose Connection

Fasten the remote fuel hose to fitting with a hose clamp. Position the hose clamp so that it will not chafe or cut into an adjacent
wiring harness.
NOTICE
Inspect the position of the hose clamp to ensure that it will not chafe or cut into the adjacent wiring harnesses.
Fuel Hose Size

Minimum fuel hose inside diameter (ID) is 9.5 mm (3/8 in.) with separate fuel hose/fuel tank pickup for each engine.
a - Hose clamp
b - Remote fuel hose
47751
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.
1. Position the remote control and outboard into neutral position.
Page 1D-12 90-8M0060785 DECEMBER 2011

2. Center the shift cable anchor pin with the neutral detent alignment mark.
a a - Shift cable anchor pin

b - Neutral detent alignment mark
b 47736
3. 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.
b. Move the remote control handle from neutral into reverse and advance the handle to full speed position. Slowly return
the handle back to the neutral position. Place a mark "b" on the cable against the cable end guide.
c. Make a center mark "c," midway between marks "a" and "b." Align the cable end guide against this center mark when
installing the cable to the engine.
6098
4. Fit the shift cable through the rigging grommet.
47738
5. Position the remote control into neutral.

6. Place the barrel cup into the barrel pocket.
7. Align the shift cable end guide with the center mark made in step 3. Place the shift cable on the anchor pin. Adjust cable
barrel so it slips freely into the barrel cup.
90-8M0060785 DECEMBER 2011 Page 1D-13

8. Secure the shift cable to the anchor pin with the bow tie clip retainer.
c d a- Shift cable end guide

a b b- Bow tie clip retainer
c- Center mark
d- Cable barrel
e- Barrel cup
e
47743
9. Lock the barrel in place with the cable latch.
a a - Cable latch
47744
10. Check shift cable adjustments as follows:
a. Shift remote control into forward. The propeller shaft should be locked in gear. If not, adjust the barrel closer to the
cable end.
b. Shift remote control into neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel away from
the cable end. Repeat steps a and b.
c. Shift remote control into reverse while turning propeller. The propeller shaft should be locked in gear. If not, adjust the
barrel away from the cable end. Repeat steps a through c.
d. Shift remote control back to neutral. The propeller shaft should turn freely without drag. If not, adjust the barrel closer
to the cable end. Repeat steps a through d.
Throttle Cable Installation

Install cables into the remote control following the instructions provided with the remote control.
Page 1D-14 90-8M0060785 DECEMBER 2011

1. Shift remote control into the neutral (N) position.
26838
2. Fit the throttle cable through the rigging grommet.
47739
3. Install the throttle cable to the throttle arm with the bow tie clip retainer.
4. Adjust the cable barrel so that the installed throttle cable will hold the throttle arm against the idle stop.
5. Place the barrel cup onto the barrel. Place the cable barrel and barrel cup into the barrel retainer.
c
b a- Bow tie retainer
b- Throttle cable end guide
c- Cable barrel
d- Barrel cup
a d
47747
6. Lock the cable in place with the cable latch.
a a - Cable latch
47748
90-8M0060785 DECEMBER 2011 Page 1D-15

Notes:
Page 1D-16 90-8M0060785 DECEMBER 2011

Storage
1
Section 1E - Storage E
Table of Contents
Storage Preparation...........................................................1E-2 Gearcase........................................................................... 1E-3
Fuel System................................................................1E-2 Positioning Outboard for Storage.......................................1E-3
Protecting External Outboard Components....................... 1E-2 Battery Storage.................................................................. 1E-3
Protecting Internal Engine Components............................ 1E-2 Winter Storage of Batteries................................................1E-3
90-8M0060785 DECEMBER 2011 Page 1E-1

Storage
Lubricant, Sealant, Adhesives

95 2-4-C with PTFE Battery terminal bolts 92-802859A 1
119 Storage Seal Rust Inhibitor Spark plug holes 92-858081K03
120 Corrosion Guard External metal surfaces 92-802878 55

Fuel System Treatment and
124 Fuel tank 92-8M0047932
Stabilizer
Storage Preparation
The major consideration in preparing your outboard for storage is to protect it from rust, corrosion, and damage caused by
freezing of trapped water.
The following storage procedures should be followed to prepare your outboard for out of season storage or prolonged storage
(two months or longer).
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
Fuel System
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage
the fuel system. If the gasoline being used contains alcohol, it is advisable to drain as much of the remaining gasoline as
possible from the fuel tank, remote fuel line, and engine fuel system.
IMPORTANT: This outboard is equipped with a closed fuel system when the engine is not running. With this closed system,
fuel within the engine's fuel system, other than the fuel tank, will remain stable during normal storage periods without the
addition of fuel treatment stabilizers.
Fill the fuel tank and engine fuel system with treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed
with the following instructions.
• Portable fuel tank ‑ Pour the required amount of Fuel System Treatment and Stabilizer (follow instructions on container)
into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel.
• Permanently installed fuel tank ‑ Pour the required amount of Fuel System Treatment and Stabilizer (follow instructions on
container) into a separate container and mix with approximately one liter (one quart) of gasoline. Pour this mixture into fuel
tank.

Fuel System Treatment
124 Fuel tank 92-8M0047932
and 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).

120 Corrosion Guard External metal surfaces 92-802878 55
Protecting Internal Engine Components

• Change the engine oil and filter.
• Disconnect the fuel pumps from the engine harness connector.
• Remove the spark plugs.
• Spray approximately 30 ml (1 fl oz) of Storage Seal Rust Inhibitor into each spark plug hole.
Page 1E-2 90-8M0060785 DECEMBER 2011

Storage

Storage Seal Rust
119 Spark plug holes 92-858081K03
Inhibitor
• Actuate key/push button start switch to crank the engine through one start cycle, which will distribute the storage seal
throughout the cylinders.
• Connect the fuel pumps to the engine harness connector.
• Install the spark plugs.
Gearcase
• Drain and refill the gearcase lubricant.
Positioning Outboard for Storage

Store outboard in an upright (vertical) position to allow water to drain out of the outboard.
NOTICE
Storing the outboard in a tilted position can damage the outboard. Water trapped in the cooling passages or rain water
collected in the propeller exhaust outlet in the gearcase can freeze. Store the outboard in the full down position.
Battery Storage
• Follow the battery manufacturer's instructions for storage and recharging.
• Remove the battery from the boat and check water level. Recharge if necessary.
• Store the battery in a cool, dry place.
• Periodically check the water level and recharge the battery during storage.
Winter Storage of Batteries

Battery companies are not responsible for battery damage, either in winter storage or in dealer stock, if the following
instructions are not observed:
1. Remove battery from its installation as soon as possible and remove all grease, sulfate, and dirt from the top surface by
running water over top of the battery. Be sure, however, the vent caps are tight beforehand and blow off all excess water
thoroughly with compressed air. Check water level, making sure the plates are covered.
2. When adding distilled water to the battery, be extremely careful not to fill more than 4.8 mm (3/16 in.) above perforated
baffles inside the battery. Battery solution or electrolyte expands from heat caused by charging. Overfilling the battery will
cause the electrolyte to overflow (if filled beyond 4.8 mm [3/16 in.] above baffles).
3. 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.

4. If specific gravity drops below 1.240, check battery for reason and recharge. When gravity reaches 1.260, discontinue
charging. To check specific gravity, use a hydrometer, which can be purchased locally.
5. Repeat preceding charging procedure every 30–45 days, as long as the battery is in storage, for best possible
maintenance during inactive periods to ensure a good serviceable battery in spring. When ready to place the battery back
in service, remove excess grease from the terminals (a small amount is desirable on terminals at all times), recharge
again, as necessary, and reinstall the battery.
90-8M0060785 DECEMBER 2011 Page 1E-3

Storage
Notes:
Page 1E-4 90-8M0060785 DECEMBER 2011

Ignition
Electrical
Section 2A - Ignition
Table of Contents 2
A
Ignition Specifications........................................................ 2A-2 Cylinder Block Coolant Temperature Sensor Removal
Electrical Components....................................................... 2A-4 .............................................................................. 2A-23
Troubleshooting Guide.......................................................2A-6 Cylinder Block Coolant Temperature Sensor
Flywheel.............................................................................2A-8 Installation............................................................. 2A-24
Engine Harness Connector................................................2A-8 Manifold Absolute Pressure (MAP) Sensor .................... 2A-25
Engine Control Module (ECM)........................................... 2A-8 Manifold Absolute Pressure Sensor Test................. 2A-25
Engine Control Module Removal................................ 2A-9 Manifold Absolute Pressure Sensor Removal.......... 2A-26
Engine Control Module Installation............................. 2A-9 Manifold Absolute Pressure Sensor Installation....... 2A-27
Wire Color Code Abbreviations........................................2A-10 Idle Air Control (IAC)........................................................2A-27
Main Power Relay (MPR)................................................ 2A-10 Idle Air Control (IAC) Testing....................................2A-28
Main Power Relay ....................................................2A-10 IAC Removal.............................................................2A-29
Main Power Relay Test.............................................2A-10 IAC Inspection and Installation................................. 2A-29
Ignition Coil...................................................................... 2A-16 Manifold Air Temperature (MAT) Sensor ........................ 2A-30
Ignition Coils............................................................. 2A-16 Manifold Air Temperature Sensor Test.....................2A-30
Ignition Coil Resistance Test.................................... 2A-17 Manifold Air Temperature Sensor Removal..............2A-31
Spark Plug Wire Resistance Test.................................... 2A-18 Manifold Air Temperature Sensor Installation...........2A-32
Crankshaft Position Sensor (CPS)...................................2A-18 Shift Position Sensor........................................................2A-32
Crankshaft Position Sensor Test.............................. 2A-18 Shift Position Sensor Test........................................ 2A-33
Crankshaft Position Sensor Removal....................... 2A-19 Shift Position Sensor Removal................................. 2A-33
Crankshaft Position Sensor Installation.................... 2A-20 Shift Position Sensor Installation.............................. 2A-34
Throttle Position Sensor (TPS)........................................ 2A-21 Oil Pressure Sensor.........................................................2A-35
Throttle Position Sensor Test................................... 2A-21 Oil Pressure Sensor Test..........................................2A-35
Cylinder Block Coolant Temperature Sensor...................2A-22 Oil Pressure Sensor Removal.................................. 2A-36
Cylinder Block Coolant Temperature Sensor Test... 2A-22 Oil Pressure Sensor Installation............................... 2A-37
90-8M0060785 DECEMBER 2011 Page 2A-1

Ignition
Full throttle RPM 5000–5800
Idle RPM 650 ± 50
Ignition type Digital inductive
Ignition timing at idle Approximately 2° BTDC; ECM controlled
Ignition timing at WOT ECM controlled
ECM overspeed limiter Activates at 5900 RPM

Loctite 567 PST Pipe Cylinder block coolant temperature sensor threads
9 92-809822
Sealant Oil pressure sensor threads
Special Tools
Spark Gap Tester 91‑850439T 1
Provides a visual indication of spark/coil efficiency.

7513
CDS G3 Diagnostic Interface Tool With

8M0046124
Harness
Provides diagnostic support for the Computer Diagnostic System.
41993
DMT 2004 Digital Multimeter 91‑892647A01
Measures RPM on spark ignition (SI) engines, ohms, amperes, AC and DC

V Hz
H z TEMP
mA
A
voltages; records maximums and minimums simultaneously, and accurately
reads in high RFI environments.
mV IG
OFF IP
TEMP
A mA COM V Hz
4516
Page 2A-2 90-8M0060785 DECEMBER 2011

Ignition
Notes:
90-8M0060785 DECEMBER 2011 Page 2A-3

Ignition
Electrical Components
21
20
1
14
2
12 3
11 1
8
9
6 7
15 21 10
5 13 8
7
6
5
16
17
18 8
7
19 8 6
7 5
6
5
49429
Page 2A-4 90-8M0060785 DECEMBER 2011

Ignition
Electrical Components
Torque
Ref. No. Qty. Description Nm lb‑in. lb‑ft
1 2 Screw (M10 x 60) 50 36.8
2 1 Alternator
3 1 Nut 4.5 39.8
4 1 Belt
5 6 Screw (M6 x 25) 10 88.5
6 6 Washer
7 6 Grommet
8 6 Bushing
9 1 Electrical cover
10 4 Relay
11 AR Fuses (20A [2]), (15A [1]), (2A [1])
12 1 Fuse cover
13 2 Cable tie retainer
14 2 Retainer
15 1 Engine control module
16 1 Fusible link
17 1 Cable
18 1 Positive cable
19 1 Negative cable
20 1 Engine harness
21 AR Cable tie
90-8M0060785 DECEMBER 2011 Page 2A-5

Ignition
Troubleshooting Guide
Spark Gap Tester 91‑850439T 1
8M0046124
Harness
1. Engine Cranks but Will Not Start

Cause Action
1.0 Weak battery or bad starter motor, battery Replace/recharge battery.
voltage drops below 11 volts while cranking (ECM Inspect the condition of the starter motor.
cuts out below 8 volts) (fuel pumps require 9 volts) Check condition of the battery terminals and cables.
Turn the key switch to the "ON" position to verify the fuel pump runs for
1.1 No fuel
five seconds and then turns off.
Measure the fuel pressure at the fuel rail.
1.2 Low fuel pressure
Fuel pressure should be 280–310 kPa (40.6–45.0 psi).
1.3 Flywheel key sheared or is not installed Remove the flywheel and inspect.
1.4 Blown fuse Inspect the fuses in the fuse holder and replace if blown.
Listen for the relay to click when the key switch is turned on. If the relay
1.5 Main power relay is not functioning does not click, inspect the harness and the connector pins for damage,
verify the 15 amp fuse is not blown.
Disconnect the engine harness from the fuel supply module.
Remove spark plugs from each cylinder.
Install the spark gap tester to each ignition coil. Crank the engine, or use
1.6 Spark plugs1. the CDS G3 Diagnostic Interface tool output load test for each ignition coil,
and observe spark. If no spark is present, inspect the fuse. If the fuse is
good, replace the appropriate ignition coil. If spark is present, replace the
spark plugs.
Disconnect the engine harness from both coils.
Measure for resistance between the engine harness coil connectors red/
yellow wires (terminal B). High resistance indicates corrosion or a
damaged splice connection in the engine harness. An open condition
indicates the harness must be repaired at the splice location or the
1.7 Spark from one coil only
harness must be replaced.
Measure for resistance between the engine harness coil connector
terminal A and the engine harness ECM connector. (Pin 32 for coil #1, pin
33 for coil #2.) High resistance indicates corrosion. An open condition
indicates the harness must be repaired or replaced.
Fuel injection system:
• Listen for injector ticking when cranking or connect a spare injector to
each respective harness.
Ignition system:
• Install the spark gap tester between the ignition coil and engine
ground. Check for strong spark while cranking the engine.
1.8 ECM not functioning • Check for battery voltage (red/blue lead) at ignition coils.
• Check for blown fuse.
• Check for battery voltage to fuse from main power relay (red/purple
lead).
• Check for a shorted stop wire (black/yellow lead).
Check all power connections.
Defective ECM.
1. Spark jumping the gap from all cylinders at the same time in the spark gap tool may cause interference in the ECM. The interference may cause
the absence of spark on some cylinders and a false diagnosis of a no spark condition. Crank the engine over with one coil spark plug wire
connected to spark gap tool at a time or use the CDS G3 Diagnostic Interface tool to fire one coil at a time.
Page 2A-6 90-8M0060785 DECEMBER 2011

Ignition
1. Engine Cranks but Will Not Start

Cause Action
Verify the magnet is not missing from end of the sensor.
Perform an ohm resistance check of the sensor. Refer to the specifications
1.9 Crankshaft position sensor is not functioning
for ohm test.
Defective crankshaft position sensor.
2. Engine Will Not Crank

Cause Action
Use the CDS G3 Diagnostic Interface tool to determine proper functioning
2.0 Defective main power relay
of the main power relay.
2.1 Main power relay fuse blown Check for blown fuse.
2.2 Lanyard stop switch is in wrong position Reset the lanyard stop switch.
3. Engine Cranks, Starts, and Stalls

Cause Action
3.0 Low fuel pressure in the fuel rail See 1.2.
3.1 Abnormally high friction in the engine Check for a scuffed piston or other sources of high friction.
3.2 Air in the fuel system/lines Crank and start the engine several times to purge. See 1.3.
3.3 Harness connections are poor from the engine
Clean and inspect all harness connections.
to the helm
3.4 Flywheel misaligned during installation Flywheel key sheared or missing. See 1.3.
4. Engine Idle is Rough

Cause Action
Replace the spark plug if carbon bridges electrode gap, if it is completely
black, or if it is not firing and is wet with fuel.
4.1 Fouled spark plug
NOTE: If the spark plug is gray or completely black with aluminum specs,
this indicates a scuffed piston.
4.2 Failed fuel injector Refer to the specifications for the ohm test.
4.3 Bad ignition coil/weak spark Refer to the specifications for the ohm test.
4.4 Flywheel misaligned during installation Flywheel key sheared or missing. See 1.3.
4.5 Engine not running on all cylinders Inspect for mechanical damage.
5. Engine Runs Rough Below 3000 RPM

Cause Action
5.2 Low fuel pressure in the fuel rail Measure fuel pressure. See 1.2.
5.3 Bad ignition coil/weak spark Refer to the specifications for the ohm test.
5.4 Engine not running on all cylinders Inspect for mechanical damage.
6. Engine Runs Rough Above 3000 RPM

Cause Action
90-8M0060785 DECEMBER 2011 Page 2A-7

Ignition
6. Engine Runs Rough Above 3000 RPM

Cause Action
6.2 Low fuel pressure in the fuel rail Measure fuel pressure. See 1.2.
Refer to the SmartCraft gauges for low oil, engine overheat, or sensor/
6.3 Speed reduction actuator out of range. The CDS G3 Diagnostic Interface tool will help
identify proper functioning of sensors/actuator.
6.4 Defective crankshaft position sensor Refer to the CDS G3 Diagnostic Interface tool for fault identification.
7. Speed Reduction (RPM Reduced to Idle)

Cause Action
7.1 Sensor/actuator is out of range Refer to the CDS G3 Diagnostic Interface tool for fault identification.
7.2 Low oil pressure Check the oil dipstick for proper oil level.
7.3 Engine overheat Check the engine cooling system for proper functioning.
8. Speed Reduction (RPM Reduced to 75%)

Cause Action
8.1 Sensor/actuator is out of range Refer to the CDS G3 Diagnostic Interface tool for fault identification.
8.2 Low oil pressure Check the oil dipstick for proper oil level.
8.3 Engine overheat Check the engine cooling system for proper functioning.
Flywheel
The flywheel is weighted and balanced to improve engine running characteristics. The flywheel is secured to the crankshaft
with a M20 x 68 screw and washer. The flywheel has two ring gears. The top ring gear is used with the starter motor to start the
engine. The lower ring gear has missing teeth at specific locations. As the lower ring gear passes the crankshaft position
sensor, an electrical pulse is generated and sent to the engine control module (ECM). The frequency of these pulses in
conjunction with the missing tooth locations on the ring gear provides crankshaft location information to the ECM. The ECM will
use this information to regulate ignition and fuel injector timing.
Engine Harness Connector

The engine harness utilizes a compact 70 pin watertight connector for the ECM. The connector is unique because it will lock
and unlock from the ECM with the lever incorporated in the connector.
The following graphic shows the pin number location on the connector.
17 1
33 18
50 34
66 51
70 69 68 67 48714
Engine Control Module (ECM)

The ECM requires 8 volts minimum to operate. If the ECM should fail, the engine will stop running. The inputs to the ECM can
be monitored and tested using the CDS G3 Diagnostic Interface tool.

8M0046124
Harness
Page 2A-8 90-8M0060785 DECEMBER 2011

Ignition
The ECM controls the following functions:
• Calculates the precise fuel and ignition timing requirements based on engine speed, throttle position, manifold absolute
pressure (MAP), manifold air temperature (MAT), and cylinder block coolant temperature.
• Directly controls: fuel injectors, ignition coils, main power relay activation, diagnostics, Engine Guardian, start relay, idle air
control (IAC), and tachometer link (analog tachometer output or link gauge driver).
• Indirectly controls the positive circuit to: fuel injectors, main power relay activation, and fuel pumps.
The ECM operates in three modes: stall, start, and run. The ECM also provides for a smooth throttle response between varying
throttle positions and engine loads. A warm‑up mode is integrated with the run mode and disengaged after the engine
accumulates a given amount of power or engine temperature.
With the ignition key switch off, 12 volts are available from the battery at the starter solenoid, power stud, and at the alternator.
Stall mode ‑ With the ignition key switch in the "ON" position, the ECM is energized and supplies power to the main power
relay for five seconds. It also provides 5 volts power to the sensors. The ECM records barometric pressure from the MAP
sensor, intake air temperature from the MAT sensor, and coolant temperature from the cylinder block coolant temperature
sensor. The ECM will use this information to establish a warm‑up strategy that will control fuel delivery and engine speed during
warm‑up and idle.
Start mode ‑ When the vessel operator turns the key switch to the "Start" position, a 12 volt signal is sent to the ECM to begin
the sequence of turning the engine over by energizing the start relay. The start relay transfers battery voltage to energize the
starter solenoid. While the engine rotates, a pulse will be generated at the crankshaft position sensor which provides the ECM
engine speed information and engages the main power relay. When the key switch is turned to the "Start" position while the
engine is running in neutral, the engine will turn off.
Run mode ‑ At approximately 500 RPM, the ECM will transition to the run mode.
• The warm‑up strategy will continue to adjust engine speed with the fuel injector pulse width and engine spark advance until
the engine accumulates a given amount of power.
• The MAT sensor, TPS sensor, and MAP sensor are monitored to determine proper spark timing and the fuel needs
necessary to develop the amount of power asked for by the operator.
Engine Control Module Removal

1. Unlatch the engine harness and remove from the ECM.
2. Remove the three screws and washers securing the ECM to the cylinder block.
a - Screws and washers securing the ECM

b - Engine harness latch
48228
Engine Control Module Installation

1. Secure the ECM to the cylinder block with three M6 x 25 screws and washers. Tighten the screws to the specified torque.
90-8M0060785 DECEMBER 2011 Page 2A-9

Ignition
2. Push the engine harness onto the ECM and latch into place.
a - Screws and washers securing the ECM

b - Engine harness latch
48228

Screws (M6 x 25) 10 88.5
Wire Color Code Abbreviations

Wire Color Abbreviations
BLK Black BLU Blue
BRN Brown GRY Gray
GRN Green ORN or ORG Orange
PNK Pink PPL or PUR Purple
RED Red TAN Tan
WHT White YEL Yellow
LT or LIT Light DK or DRK Dark
Main Power Relay (MPR)

Main Power Relay
The main power relay is located within the electrical cover on the port side of the engine. The MPR is controlled by the ECM.
The main power relay supplies 12 volts to the fuel pumps, ignition coils, fuel injectors, and the alternator.
48215
Main Power Relay Test

The main power relay can be tested with the CDS G3 Diagnostic Interface tool.
Page 2A-10 90-8M0060785 DECEMBER 2011

Ignition

8M0046124
Harness
48843
i
h
f
j
e
g
d
c
k
b
a 67
70
68
69
51
66
50
34
33
18
1
17
a- ECM connector
b- Main power relay
c- 15 amp fuse
d- ECM ground
e- Starter
f- Power stud
g- Battery ground (engine)
90-8M0060785 DECEMBER 2011 Page 2A-11

Ignition
h- Neutral start safety switch (remote control or tiller handle)
i- Key switch
j- Engine harness to boat harness connector
k- Battery
Main Power Relay Removal

1. Disconnect the battery cables from the battery.
2. Disconnect the helm harness from the engine harness.
3. Remove the engine harness from the retainer.
4. Unlatch the engine harness and remove from the ECM.
b a - Helm harness
b - Retainer
c - Engine harness latch
c
a
48217
5. Remove the three screws and washers securing the electrical cover to the cylinder block.
48216
6. Rotate the electrical cover to access the components on the cover.
Page 2A-12 90-8M0060785 DECEMBER 2011

Ignition
7. Cut five cable ties securing the engine harness to the electrical cover. Pull the engine harness out of the electrical cover
openings.
48218
8. Unlatch all of the relays and remove the main power relay from the electrical cover.
9. Remove the main power relay from the engine harness connector.
a- Main power relay

b- Start relay
c- Up relay
d d- Down relay
c
a
48219
10. Inspect the engine harness relay connector for damaged spade terminals or loose wires.
Main Power Relay Resistance Test

Use the DMT 2004 digital multimeter for all of the following tests.
1. Perform a visual inspection of the main power relay spade terminals. Look for loose or corroded spade terminals.
90-8M0060785 DECEMBER 2011 Page 2A-13

Ignition
2. Measure the resistance between the main power relay coil terminal 85 (red/purple) and terminal 86 (yellow/purple).
Replace the relay if the resistance is not within the specifications.
87
87a
86 85
30
48220
Meter Test Leads

Meter Scale Reading (Ω)
Red Black
Terminal 85 Terminal 86 Auto ohms 85 ± 10
Main Power Relay Installation

1. Install the main power relay into the engine harness connector.
a- Main power relay

b- Start relay
c- Up relay
d d- Down relay
c
a
48219
2. Install the main power relay into the electrical cover. Push the relay into the electrical cover to lock the engine harness
connector into the electrical cover.
3. Verify all of the engine harness relay connectors are locked onto the electrical cover.
4. Push the engine harness into the electrical cover openings.
Page 2A-14 90-8M0060785 DECEMBER 2011

Ignition
5. Secure the engine harness to the electrical cover with five cable ties.
48218
6. Secure the electrical cover to the cylinder block with three M6 x 25 screws and washers. Tighten the screws to the
specified torque.
48216

Electrical cover screws M6 x 25 10 88.5
7. Push the engine harness onto the ECM and latch into place.
8. Secure the engine harness with the retainer.
90-8M0060785 DECEMBER 2011 Page 2A-15

Ignition
9. Connect the helm harness to the engine harness.
b a - Helm harness
b - Retainer
c - Engine harness latch
c
a
48217
10. Connect the battery cables to the battery.
Ignition Coil
Ignition Coils
The primary (+) side of the ignition coil receives battery voltage from the main power relay. When the key switch is turned "ON,"
the main power relay ground circuit is completed through the ECM. The main power relay transfers battery voltage to the two
coils. The coils are protected with a 20 amp fuse. The negative side of the coil is connected to the engine ground through the
ECM. When this circuit is closed, a magnetic field is built up in the ignition coils. When the ECM is supplied with a trigger signal,
the ECM opens the circuit and the magnetic field collapses across the coil secondary winding, creating a high voltage charge
that is sent to the spark plugs. Each coil supplies spark to 2 cylinders. The ignition system is a wasted spark design, where
each coil fires once every revolution.
Ignition Coil Voltage Test

The ignition coils can be tested with the CDS G3 Diagnostic Interface tool.

8M0046124
Harness
a - Cylinder 1 and 4 coil

b - Cylinder 2 and 3 coil
b
48869
! WARNING
High voltage is present any time the key is turned on, especially when starting or operating the engine. Do not touch ignition
components or metal test probes and stay clear of spark plug leads when performing live tests.
1. Disconnect the connector from both of the coils.

2. Perform a visual inspection of the pins at the coil and the wires coming to the connector. Look for broken, bent, and
corroded pins at the coil; and loose, broken, or corroded wires at the connector.
Page 2A-16 90-8M0060785 DECEMBER 2011

Ignition
3. Use the DMT 2004 digital multimeter to perform a voltage check of the wiring between the ignition coil connector and the
ECM connector. Set the meter to DC volts.
4. Turn the ignition key to the "ON" position. Battery voltage will only be available when the main power relay is active.
NOTE: All 12 VDC power wires for the coils are spliced together. Unless all the coils have failed, the most likely failure
would be at the splice point, connector, or between the connector and the splice point.
d e
c
b
RED/YEL
GRN/RED
1 18 34 51
67 a
C D
68
69
70
48926
17 33 50 66
a- ECM connector
b- Main power relay
c- 20 amp fuse
d- Ignition coil (cylinder 1 and 4)
e- Ignition coil (cylinder 2 and 3)
5. If battery voltage is not present on the red/yellow wire to the engine ground, there is an open circuit between the splice
point and the red/yellow wire connector.
Ignition Coil Resistance Test

1. Remove the spark plug lead from the ignition coil. Twist the ignition coil boot slightly while removing.
2. Use a DMT 2004 digital multimeter and perform the following test.
c
a - Pin A
a b b - Pin B
c - Coil towers
42625
90-8M0060785 DECEMBER 2011 Page 2A-17

Ignition
Ignition Coil Resistance Test (Ω)

Between coil towers 7200–8800
Between pin A and B 0.3–0.5
Spark Plug Wire Resistance Test

Each spark plug wire should be measured for a specific range of resistance. The resistance should be measured from one end
to the other. Different meters may show different resistance numbers. A digital meter is more accurate than an analog meter.
Because there are many different manufacturers of meters, if the meter reads within 10% of the stated specifications, consider
the resistance within an acceptable range.
a - Coil tower end

b - Spark plug end
b
49262
Spark Plug Wire Resistance

Coil wire 1 and 4 1636–2101 Ω
Coil wire 2 1384–1792 Ω
Coil wire 3 1270–1652 Ω
Crankshaft Position Sensor (CPS)

The CPS is located at the top of the cylinder block next to the flywheel. The sensor contains a magnet which is positioned next
to the flywheel's lower ring gear. This ring gear has missing teeth at specific locations. The close proximity of the CPS magnet
to the teeth allows a magnetic field to be created each time a tooth passes the sensor. This field collapses and creates an AC
voltage pulse. This AC pulse is sent to the ECM. The timing and frequency of these pulses allows the ECM to regulate ignition
and fuel injector timing. If the crankshaft position sensor fails, the engine will run rough or stop running.
48168
Crankshaft Position Sensor Test

1. Perform a visual inspection of the sensor. The tip of the sensor must be flush across the end; if not, replace the sensor.
2. The tip of the sensor must be clean. There should be no metal debris (ring gear filings) attached to the sensor tip.
NOTE: There is a magnet mounted in the sensor's tip. If the magnet is missing, the sensor will not operate properly.
3. Inspect the flywheel timing wheel for:
• Excessive corrosion
Page 2A-18 90-8M0060785 DECEMBER 2011

Ignition
• The teeth should have square edges

• There should only be one missing tooth on either side of the two teeth, three teeth, or four teeth groups
4. Replace the flywheel if it does not meet inspection requirements.
5. Disconnect the engine harness connector from the sensor and perform a visual inspection of the sensor pins and the wires
coming from the connector. Look for broken, bent, or corroded pins at the sensor; and loose, broken, or corroded wires at
the connector.
6. Use the DMT 2004 digital multimeter to measure the resistance across the crankshaft position sensor pins. Replace the
crankshaft position sensor if out of specification.
NOTE: If the engine problem occurs above 3000 RPM (runs rough, no high RPM), the ohm test of the crankshaft position
sensor may be good but the sensor can still be defective.
c d a- Magnet
b- CPS
c- Pin 1 (red)
d- Pin 2 (white)
a 17025
Crankshaft Position Sensor

Resistance at 21 °C (70 °F) 300–350 Ω
7. Connect the harness to the crankshaft position sensor. Disconnect the 70 pin connector from the ECM and measure the
resistance between pins 13 and 14. The resistance must be within specification. If not, repair the wiring between the ECM
and the crankshaft position sensor.
18 34 51
1 a - ECM connector
67 a b - CPS
68
b
69
70 48981
17 33 50 66
Meter Test Leads

Red Black
Pin 13 Pin 14 Auto 300–350 at 21 °C (70 °F)
Crankshaft Position Sensor Removal

1. Remove flywheel cover.
90-8M0060785 DECEMBER 2011 Page 2A-19

Ignition
2. Cut the cable tie securing the cylinder block coolant temperature sensor connector and the crankshaft position sensor to
the engine harness.
3. Disconnect the engine harness connector from the crankshaft position sensor.
4. Remove the two screws securing the crankshaft position sensor to the cylinder block.
b a - Cable tie
b - Engine harness connector
c - Screws securing the crankshaft position sensor (2)
a
48169
Crankshaft Position Sensor Installation

1. Install the crankshaft position sensor onto the cylinder block and secure with two M5 x 13 screws. Tighten the screws to
the specified torque.
2. Guide the connector under the engine temperature sensor harness.
3. Connect the engine harness connector to the crankshaft position sensor.
4. Secure the cylinder block coolant temperature sensor connector and the crankshaft position sensor to the engine harness
with a cable tie.
b a - Cable tie
c - Screws securing the crankshaft position sensor (2)
a
48169

CPS screw (M5 x 13) 5.1 45
5. Install the flywheel cover.
Page 2A-20 90-8M0060785 DECEMBER 2011

Ignition
Throttle Position Sensor (TPS)

The TPS is located on the throttle body and is in direct contact with the throttle shaft. The TPS transmits throttle angle
information to the ECM, which regulates the fuel injector volume (pulse width) and ignition timing based on the TPS position
along with other cylinder block sensors. Should the sensor fail, a warning horn will sound and the engine RPM will be reduced
by the ECM. TPS settings are not adjustable. TPS settings can be monitored with the CDS G3 Diagnostic Interface tool through
the ECM. Voltage change should be smooth from idle to wide‑open throttle. If the voltage change is erratic, the TPS is
defective.
47910
Throttle Position Sensor Test

The throttle position sensor can be tested with the CDS G3 Diagnostic Interface tool.

8M0046124
Harness
1. Disconnect the engine harness from the TPS.

2. Perform a visual inspection of the throttle position sensor pins and the wires coming from the connector. Look for broken,
bent, or corroded pins at the throttle position sensor; and loose, broken, or corroded pins at the engine harness connector.
3. Disconnect the engine harness connector from the ECM.
4. Use the DMT 2004 digital multimeter to perform an ohm check of the wiring between the throttle position sensor connector
and the ECM connector.
NOTE: All sensor ground wires are spliced together and connect to the ECM at pin 42. Unless there are multiple sensor
failures, the most likely failure would be at the splice point, connector, or between the connector and the splice point.
b a- ECM connector
d b- Throttle position sensor
c- Purple/yellow
e d- Lt blue/white
c e- Black/orange
1 18 34 51 a
67
68
69
70 48929
17 33 50 66
90-8M0060785 DECEMBER 2011 Page 2A-21

Ignition
Meter Test Leads

Red Black
Pin 42 Sensor connector A (black/orange) Auto Less than 1
Pin 53 Sensor connector C (Lt blue/white) Auto Less than 1
Pin 34 Sensor connector B (purple/yellow) Auto Less than 1
NOTE: Refer to Section 3C ‑ Throttle Body to remove and replace the TPS.
Cylinder Block Coolant Temperature Sensor

The cylinder block coolant temperature sensor is located near the thermostat housing. It is a thermistor immersed in the engine
coolant path. It supplies the ECM with engine temperature information. The ECM adjusts the timing and the amount of fuel
delivered according to the water temperature in the cylinder block. Low coolant temperature produces high resistance, while
high temperature causes low resistance.
48170
Cylinder Block Coolant Temperature Sensor Test

The CDS G3 Diagnostic Interface tool will help determine the proper functioning of the cylinder block coolant temperature
sensor by providing a numerical readout of the cylinder block coolant temperature before and after the engine is started. With
the engine not running, the engine block temperature should be approximately the same as the ambient air temperature. After
the engine is started, the temperature sensor should indicate a rise in cylinder block coolant temperature to approximately
60–70 °C (140–158 °F). Outside air temperature and the temperature of the water that the engine is operating in will directly
affect the engine block temperature.
1. With the engine running and the CDS G3 Diagnostic Interface tool connected to the engine, if the cylinder block coolant
temperature sensor does not appear to be indicating a temperature change, shake or move the sensor harness and
connector. If the temperature begins to change, look for a broken, loose, or corroded wire.

8M0046124
Harness
2. Disconnect the engine harness from the cylinder block coolant temperature sensor.
3. Perform a visual inspection of the cylinder block coolant temperature sensor pins and the wires coming from the connector.
Look for broken, bent, or corroded pins at the cylinder block coolant temperature sensor; and loose, broken, or corroded
wires at the connector.
Page 2A-22 90-8M0060785 DECEMBER 2011

Ignition
4. The cylinder block coolant temperature sensor can be tested with an ohmmeter by removing the cylinder block coolant
temperature sensor from the cylinder block and heating or cooling the end of the cylinder block coolant temperature sensor
in a temperature controlled media. If the readings do not match those in the table, replace the cylinder block coolant
temperature sensor and retest.
b a - Pin A (black/orange)
b - Cylinder block coolant temperature sensor
c - Pin B (tan/black)
a c
16973
Meter Test Leads

Temperature Reading (Ω)
Red Black
0 °C (32 °F) 32.6 kΩ ± 1.14
25 °C (77 °F) 10.0 kΩ ± 1.14
Pin B (tan/black) Pin A (black/orange)
50 °C (122 °F) 3.6 kΩ ± 1.50
100 °C (212 °F) 678.0 Ω ± 2.36
5. If the ohm check indicates that the cylinder block coolant temperature sensor is serviceable, perform an ohm check of the
wiring between the cylinder block coolant temperature sensor connector and the ECM connector.
a
a - ECM connector
1 18 34 51
67
b - Cylinder block coolant
temperature sensor
21 b
68
BLK/ORN
TAN/BLK
69
42
70
66 48980
17 33 50
Meter Test Leads

Red Black
Pin 42 Sensor connector pin B (black/orange) Auto Less than 1
Pin 21 Sensor connector pin A (tan/black) Auto Less than 1
Cylinder Block Coolant Temperature Sensor Removal

1. Remove the flywheel cover.
2. Cut the cable tie securing the cylinder block coolant temperature sensor connector and the crankshaft position sensor to
the engine harness.
3. Disconnect the engine harness connector from the cylinder block coolant temperature sensor.
90-8M0060785 DECEMBER 2011 Page 2A-23

Ignition
4. Remove the cylinder block coolant temperature sensor from the cylinder block.
a - Cable tie securing the engine harness connector

b and cylinder block coolant temperature sensor
a c - Cylinder block coolant temperature sensor
48171
Cylinder Block Coolant Temperature Sensor Installation

1. Install a new O‑ring onto the cylinder block coolant temperature sensor.
13384
2. Apply Loctite 567 PST Pipe Sealant onto the threads of the cylinder block coolant temperature sensor.

Loctite 567 PST Pipe
9 Cylinder block coolant temperature sensor threads 92-809822
Sealant
3. Install the cylinder block coolant temperature sensor into the cylinder block. Tighten the sensor to the specified torque.
4. Connect the engine harness to the cylinder block coolant temperature sensor.
5. Secure the cylinder block coolant temperature sensor connector and the crankshaft position sensor to the engine harness
with a cable tie.
a - Cable tie securing the engine harness connector

b and cylinder block coolant temperature sensor
a c - Cylinder block coolant temperature sensor
48171

Cylinder block coolant temperature sensor 15 132.7
Page 2A-24 90-8M0060785 DECEMBER 2011

Ignition
Manifold Absolute Pressure (MAP) Sensor

The MAP sensor measures the changes in the intake manifold pressure. It is located on the intake manifold. When the ignition
key switch is turned to the "ON" position, the MAP sensor reads the ambient atmospheric pressure. This information is used by
the ECM as an indication of altitude. The MAP sensor will change as a result of engine load and speed changes. The changing
data is used to calculate air density and determine the engine's air mass flow rate, which in turn determines the required fuel
metering for optimum combustion.
47909
Manifold Absolute Pressure Sensor Test

The CDS G3 Diagnostic Interface tool will display the functioning of the MAP sensor by providing a numerical readout of the
sensor after the engine is started.
Manifold Absolute Pressure (MAP) Sensor Readings

At idle (neutral) 34–40 kPa (4.9–5.8 psi)
At wide‑open throttle 93.5–98.5 kPa (13.5–14.2 psi)
1. Start the engine and connect the CDS G3 Diagnostic Interface tool to the engine. If the MAP sensor does not appear to be
indicating a pressure change, shake or move the sensor harness and connector. If the pressure begins to change, look for
broken, loose, or corroded wires.

8M0046124
Harness
2. Turn the ignition key switch to the "OFF" position. Disconnect the engine harness from the MAP sensor.
3. Visually inspect the MAP sensor pins and the wires coming from the connector. Look for broken, bent, or corroded pins at
the MAP sensor; and loose, broken, or corroded wires at the connector.
4. Use the DMT 2004 digital multimeter to perform an ohm check between MAP sensor pins A, B, and C.
d a- Pin C (purple/yellow)
b- Pin A (black/orange)
c- Pin B (yellow)
d- MAP sensor
a b
c
23432
90-8M0060785 DECEMBER 2011 Page 2A-25

Ignition
Meter Test Leads Reading (Ω)

Meter Scale
Red Black At 21 °C (70 °F)
A B Auto 4.28 kΩ ± 30%
A C Auto 6.48 kΩ ± 30%
B A Auto 4.29 kΩ ± 30%
B C Auto 6.48 kΩ ± 30%
C A Auto 1.9 kΩ ± 30%
C B Auto 6.8 kΩ ± 30%
5. If the ohm check of the MAP sensor indicates that the MAP sensor is serviceable, perform an ohm check on the wiring
between the MAP sensor connector and the ECM connector.
a
1 18 34 51
67
68
b
69
70
66 48979
17 33 50
a - ECM connector
b - MAP sensor
Meter Test Leads

Red Black
Pin 42 Sensor connector pin A (black/orange) Auto Less than 1
Pin 22 Sensor connector pin B (yellow) Auto Less than 1
Pin 34 Sensor connector pin C (purple/yellow) Auto Less than 1
Manifold Absolute Pressure Sensor Removal

1. Remove the screw securing the MAP sensor retaining bracket.
2. Pull the MAP sensor from the intake manifold.
Page 2A-26 90-8M0060785 DECEMBER 2011

Ignition
3. Disconnect the engine harness from the MAP sensor.
a- Screw
c d b- Retaining bracket
c- MAP sensor
d- Engine harness
b
48193
Manifold Absolute Pressure Sensor Installation

1. Connect the engine harness to the MAP sensor.
2. Push the MAP sensor into the intake manifold opening.
3. Install the MAP sensor retaining bracket into the intake manifold tab.
4. Secure the retaining bracket with a screw. Tighten the screw to the specified torque.
a- Screw
c d b- Retaining bracket
c- MAP sensor
d- Engine harness
b
48193

MAP sensor retaining bracket screw 1.7 15
Idle Air Control (IAC)

The IAC is located on the intake manifold. One side of the IAC is exposed to the ambient air pressures under the cowl. The
other side is exposed to the intake manifold pressures. The flow passage has a control orifice which is open or closed with the
stopper on the end of the IAC valve.
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Ignition
The IAC is normally open to allow ambient air pressure into the manifold for a barometric air pressure reading. When the IAC is
activated, the armature lifts, opening the orifice. During engine start‑up, manifold vacuum pressure (low pressure) causes the
stopper to close.
48194
Idle Air Control (IAC) Testing

The CDS G3 Diagnostic Interface tool will display the duty cycle of the IAC by providing a numerical percentage of the time the
IAC solenoid is active as a fraction of the total time under consideration.

8M0046124
Harness
1. Disconnect the engine harness from the IAC.

2. Disconnect the engine harness connector from the ECM.
3. Use the DMT 2004 digital multimeter to perform an ohm check on the engine harness between the IAC connector and the
ECM connection. Set the meter to read ohms, auto scale.
b d
c
WHT/LT BLU
RED/BLU
1 18 34 51 a A B
67
68
57 RED/BLU
69
58 RED/BLU
70 48927
17 33 50 66
a- ECM connector
b- IAC
c- Main power relay
d- 20 amp fuse
Page 2A-28 90-8M0060785 DECEMBER 2011

Ignition
Meter Test Leads

Red Black
Pin 3 IAC engine harness connector pin 1 (white/Lt blue) Auto Less than 1
Pin 57 or 58 IAC engine harness connector pin 2 (red/blue) Auto Less than 1

4. If the result of the test is not within specifications, check for corrosion or an open connection. Repair as needed.
IAC Removal
1. Disconnect the engine harness connector from the IAC.
2. Remove the two screws securing the IAC to the intake manifold.
3. Remove the IAC from the intake manifold.
a - Screws securing the IAC (one is hidden)

a b - Engine harness connector
48197
IAC Inspection and Installation

1. Inspect the IAC O‑rings for deformation or damage. Replace as required.
48198
2. Install the IAC onto the intake manifold and secure with two screws. Tighten the screws to the specified torque.
90-8M0060785 DECEMBER 2011 Page 2A-29

Ignition
3. Connect the engine harness connector onto the IAC.
a - Screws securing the IAC (one is hidden)

a b - Engine harness connector
48197

Screws securing the IAC 8 70.8
Manifold Air Temperature (MAT) Sensor

The MAT sensor is a thermistor that controls a signal voltage to the ECM. It is located on the intake manifold, close to the fuel
rail. It informs the ECM of the air temperature inside the intake manifold. The ECM adjusts the fuel injection duration needed to
run the engine at optimum efficiency according to the MAT information. When the intake air is cold, the sensor resistance is
high. As the air temperature rises, resistance lowers.
48172
Manifold Air Temperature Sensor Test

The CDS G3 Diagnostic Interface tool will determine the proper functioning of the MAT sensor by providing a numerical readout
of the sensor temperature before and after the engine is started. With the engine not running, intake air temperature should be
approximately the same as the ambient air temperature with a cold engine. After the engine is started, the temperature sensor
should indicate a rise in air intake temperature. Outside air temperature will directly affect the engine manifold air intake
temperature.
1. Start the engine and connect the CDS G3 Diagnostic Interface tool to the engine. If the MAT sensor does not appear to be
indicating a temperature change, shake or move the sensor harness and connector. If the temperature begins to change,
look for a broken, loose, or corroded wire.

8M0046124
Harness
2. Disconnect the engine harness from the MAT sensor.
3. Visually inspect the MAT sensor pins and the wires coming from the engine harness connector. Look for broken, bent, or
corroded pins at the MAT sensor; and loose, broken, or corroded wires at the engine harness connector.
4. Use the DMT 2004 digital multimeter to test the MAT sensor. Remove the MAT sensor from the intake manifold.
Page 2A-30 90-8M0060785 DECEMBER 2011

Ignition
5. Immerse the MAT sensor into a temperature controlled media. If the readings do not match those in the table, replace the
MAT sensor and retest.
a - Pin A (tan)
b - Pin B (black/orange)
c - MAT sensor
c
b 17003
Meter Test Leads

Temperature Reading (Ω)
Red Black
0 °C (32 °F) 6.5 kΩ ± 5%
15 °C (59 °F) 3.2 kΩ ± 5%
Pin A (tan) Pin B (black/orange)
25 °C (77 °F) 2.1 kΩ ± 5%
100 °C (212 °F) 0.15 kΩ ± 5%
6. If the ohm check of the MAT sensor indicates that the MAT sensor is serviceable, perform an ohm check of the wiring
between the sensor connector and the ECM connector.
a - ECM connector
b - MAT sensor
b
34 51
1 18 a
67
68
69
70
66 48935
17 33 50
Meter Test Leads

Red Black
Pin 42 Sensor connector pin B (black/orange) Auto Less than 1
Pin 20 Sensor connector pin A (tan) Auto Less than 1
Manifold Air Temperature Sensor Removal

1. Cut the cable tie securing the engine harness to the MAT sensor.
2. Disconnect the engine harness connector from the MAT sensor.
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Ignition
3. Remove the two screws securing the MAT sensor to the intake manifold and remove the MAT sensor.
a - MAT sensor mounting screw (2)

b - Cable tie
b
48182
Manifold Air Temperature Sensor Installation

1. Install a new O‑ring onto the MAT sensor.
13378
2. Install the MAT sensor on the intake manifold. Tighten the MAT sensor mounting screws to the specified torque.
3. Connect the engine harness to the MAT sensor.
4. Secure the engine harness to the MAT sensor with a cable tie.
a - MAT sensor mounting screw (2)

b - Cable tie
b
48182

Screw (M4 x 16) 1.7 15
Shift Position Sensor

The shift position sensor is mounted on the shift rail located on the starboard side of the engine. The shift position sensor is a
linear motion detection that is similar to the type of sensor used to determine the position of a throttle shaft. The shift position
sensor is preloaded to approximately the middle of the sensor travel when installed on the shift rail and the drive unit is in
neutral.
Page 2A-32 90-8M0060785 DECEMBER 2011

Ignition
Activation of the shift position sensor occurs with a cantilever actuator that is connected to the shift link. When the remote
control handle is moved to a gear position, the cantilever actuator that is connected to the shift link rotates the shift position
sensor. The linear motion of the shift position sensor is monitored by the ECM. The ECM determines a timing strategy based
on the general position and the direction of travel the sensor is moving.
The ECM is programmed to monitor relatively large windows of shift position. Each window is programmed into the ECM as a
specific number of counts. When the ECM reads the sensor position while at a specific count range, the spark timing will start
to fluctuate several degrees positive and negative to assist with removing the load on the shift clutch. This unloading of the shift
clutch facilitates an easy shift effort for the operator. While the shift position sensor is in the unload window count, the engine
may run slightly rough for a very short time. Shifting with a normal smooth, quick effort, may not show any significant running
characteristic change.
Shift Position Sensor Test

The shift position sensor can be monitored for proper operation with the CDS G3 Diagnostic Interface tool.

8M0046124
Harness
1. Disconnect the engine harness from the shift position sensor.

2. Perform a visual inspection of the shift position sensor pins and the wires coming from the connector. Look for broken,
bent, or corroded pins at the throttle position sensor; and loose, broken, or corroded pins at the engine harness connector.
3. Disconnect the engine harness 70 pin connector from the ECM.
4. Use the DMT 2004 digital multimeter to perform an ohm check of the wiring between the shift position sensor connector
and the ECM connector.
b a- ECM connector
d b- Shift position sensor
c- Purple/yellow
c e d- Blue/yellow
e- Black/orange
1 18 34 51
67
a
68
69
70
33 50 66 48936
17
Meter Test Leads

Red Black
Pin 42 Sensor connector A (black/orange) Auto Less than 1
Pin 54 Sensor connector C (blue/yellow) Auto Less than 1
Pin 34 Sensor connector B (purple/yellow) Auto Less than 1
Shift Position Sensor Removal

1. Disconnect the engine harness connector from the shift position sensor.
90-8M0060785 DECEMBER 2011 Page 2A-33

Ignition
2. Remove the screw securing the shift position sensor to the shift rail and remove the shift position sensor.
c a- Engine harness connector

b- Shift position sensor
b c- Cantilever actuator
d d- Screw securing the shift position sensor
48199
Shift Position Sensor Installation

1. Secure the cantilever actuator with your fingers and install the shift position sensor onto the actuator.
48200
2. Rotate the cantilever actuator towards the front of the engine.

3. Rotate the shift position sensor clockwise and install onto the shift rail antirotation pin.
4. Secure the shift position sensor with a M4 x 13 screw. Tighten the screw to the specified torque.
5. Connect the engine harness connector to the shift position sensor.
a- Engine harness connector

b- Shift position sensor
b c- Screw securing the shift position sensor
c d- Shift rail antirotation pin
48201

Screw (M4 x 13) 8 70.8
Page 2A-34 90-8M0060785 DECEMBER 2011

Ignition
Oil Pressure Sensor

The oil pressure sensor measures the engine oil pressure. It is located on the starboard side of the cylinder block below the
starter. In the event of low oil pressure, the ECM will limit engine power based on the amount of oil pressure available at a
specific engine RPM.
48687
Oil Pressure Sensor Test

The CDS G3 Diagnostic Interface tool will help determine the proper functioning of the oil pressure sensor by providing a
numerical readout of the sensor after the engine is started.
1. Connect the CDS G3 Diagnostic Interface tool to the engine. If the oil pressure sensor does not appear to be indicating a
pressure change with the engine running at a normal operating temperature, shake or move the sensor harness and
connector. If the pressure begins to change, look for broken, loose, or corroded wires.

8M0046124
Harness
Oil Pressure Sensor

2. Disconnect the engine harness from the oil pressure sensor.
3. Visually inspect the pins of the oil pressure sensor and the wires coming from the engine harness connector. Look for
broken, bent, or corroded pins at the oil pressure sensor; and loose, broken, or corroded wires at the engine harness
connector.
4. Use the DMT 2004 digital multimeter to check the oil pressure sensor resistance between pins A, B, and C at 21 °C
(70 °F).
a- Pin A (black/orange)
d a b- Pin B (purple/yellow)
b
c- Pin C (Lt blue)
d- Oil pressure sensor
c
17006
90-8M0060785 DECEMBER 2011 Page 2A-35

Ignition
Meter Test Leads Reading (Ω)

Meter Scale
Red Black At 21 °C (70 °F)
A B Auto 112.0 kΩ ± 30%
A C Auto 260.0 kΩ ± 30%
B A Auto 112.0 kΩ ± 30%
B C Auto 230.0 kΩ ± 30%
C A Auto 260.0 kΩ ± 30%
C B Auto 144.0 kΩ ± 30%
5. If the ohm check of the oil pressure sensor indicates that the sensor is serviceable, perform an ohm check of the sensor
wiring between the sensor connector and the ECM connector.
1 18 34 51
c
67 a
b
68
d
e
69
70
17 33 50 66
48982
a- ECM connector
b- Oil pressure sensor
c- Purple/yellow
d- Black/orange
e- Lt blue
Meter Test Leads

Red Black
Pin 42 Sensor connector pin 1 (black/orange) Auto Less than 1
Pin 34 Sensor connector pin 2 (purple/yellow) Auto Less than 1
Pin 12 Sensor connector pin 3 (Lt blue) Auto Less than 1
Oil Pressure Sensor Removal

1. Disconnect the engine harness connector from the oil pressure sensor.
Page 2A-36 90-8M0060785 DECEMBER 2011

Ignition
2. Remove the oil pressure sensor from the cylinder block.
a - Engine harness connector

a
48688
Oil Pressure Sensor Installation

1. Install a new O‑ring onto the oil pressure sensor.
13393
2. Apply Loctite 567 PST Pipe Sealant to the threads of the sensor.

9 Oil pressure sensor threads 92-809822
Sealant
3. Install the oil pressure sensor onto the cylinder block. Tighten the sensor to the specified torque.
4. Connect the engine harness connector to the oil pressure sensor.

a
48688

Oil pressure sensor 15 132.7
90-8M0060785 DECEMBER 2011 Page 2A-37

Ignition
Notes:
Page 2A-38 90-8M0060785 DECEMBER 2011

Charging and Starting Systems
Electrical
Section 2B - Charging and Starting Systems
Table of Contents 2
B
Charging and Starting Specifications.................................2B-2 Diagnosis of Alternator System on the Engine........... 2B-8
Battery................................................................................2B-3 Alternator System Circuitry Test................................. 2B-9
Battery Cable Test...................................................... 2B-3 Alternator Removal................................................... 2B-11
Original Battery Cable Length and Gauge Shipped Alternator Installation................................................ 2B-13
with Engine..............................................................2B-4 Starter System................................................................. 2B-15
Battery Cable Size for Outboard Models.................... 2B-4 Starter Motor Amp Draw........................................... 2B-15
Replacement Parts..................................................... 2B-6 Starter System Description....................................... 2B-15
Recommended Battery............................................... 2B-6 Starting System Components................................... 2B-15
Charging a Discharged Battery...................................2B-6 Starter Circuit Troubleshooting................................. 2B-16
Winter Storage of Batteries.........................................2B-6 Starter Removal........................................................2B-19
Alternator System.............................................................. 2B-7 Starter Installation.....................................................2B-21
System Components.................................................. 2B-7 Key Switch Test (Four Position)............................... 2B-22
Alternator Description................................................. 2B-8
90-8M0060785 DECEMBER 2011 Page 2B-1


Alternator output (regulated)
Voltage set point 14.4 ± 0.4 V
Ignition switch "OFF" 1.0 mA or less
Regulator current draw1.
Ignition switch "ON" 350 mA or less
Starter internal drive reduction ratio 6:1
Starter draw (under load) at 25 °C (77 °F) 150–225 A
Starter draw (no load) at 25 °C (77 °F) 50–70 A
Pull in coil 30 A
Hold coil 10 A
Starter solenoid
Pull in coil resistance 0.2 ± 10%
Hold coil resistance 0.8 ± 10%
Minimum brush length 6.54 mm (0.25 in.)
Starting battery rating
1000 minimum marine cranking
Required USA and Canada (SAE) starting battery type amps (MCA), 800 cold cranking
amps (CCA, or 180 amp hour (Ah)

Alternator output wire connection
25 Liquid Neoprene Starter solenoid power connections 92- 25711 3
Ground wire connections
Special Tools

V Hz
H z TEMP
mA
A
mV IG
OFF IP
TEMP
A mA COM V Hz
4516
1. All model alternator specifications require an amperage draw of less than 1.0 mA with the ignition key in the "OFF" position and an amperage
draw of not more than 350.0 mA with key in the "ON" position.
Page 2B-2 90-8M0060785 DECEMBER 2011


8M0046124
Harness
41993
12 Volt Shunt Tool 91‑889675A01
Connects to the 14 pin engine harness. Turns on the ECM/PCM without the use
of the vessel engine control harness. Used for troubleshooting purpose only.
8036
Battery
Battery Cable Test
This test is used to determine if there is excessive resistance in the battery's positive or negative cables, or if the cable is sized
properly to carry the necessary current needed to crank the engine at the proper RPM.
IMPORTANT: This test must be performed while the starter is cranking the engine. This engine starter is controlled by the
ECM. The starter can be engaged with the key switch or the CDS G3 Diagnostic Interface tool. Ignore any voltage readings
taken without the circuit under load.
! WARNING
Moving parts can cause serious injury or death. Wear eye protection and keep hands, hair, and clothing away from moving
parts when performing tests or checking adjustments on an operating engine.
1. Perform a load test on the battery following the instructions supplied with the load tester. Ensure the battery is brought to a
full charge after being tested.
2. Disconnect the fuel supply module fuel pump harness connector from the engine harness.
3. Connect a fuel pressure gauge to the Schrader valve on the fuel rail and release the fuel pressure into an appropriate
container. Ensure there is no spilled fuel while performing the following tests.
4. Engage the engine start process with the key switch or the CDS G3 Diagnostic Interface tool. While the starter spins the
engine over, measure the voltage across the battery posts, not the cable clamps. Record the voltage reading. If the voltage
is less than 10 VDC, replace the battery.
NOTE: The voltage reading in step 4 is the base voltage. The base voltage reading will be compared to the voltage
readings obtained in the following steps.
5. Wait 30 seconds and engage the engine start process with the key switch or the CDS G3 Diagnostic Interface tool. While
the starter spins the engine over, measure the voltage from the battery positive post (not the cable clamp) to the starter
post (the stud where the battery positive cable is connected). Record the voltage reading.
6. Wait 30 seconds and engage the engine start process with the key switch or the CDS G3 Diagnostic Interface tool. While
the starter spins the engine over, measure the voltage from the starter case to the battery negative post (not the cable
clamp). Record the voltage reading.
7. If the voltage reading in step 5 was more than 1.0 VDC different from the base voltage reading:
a. Check the cable connections for tightness and corrosion.
b. If the cable is tight and not corroded, replace the cable with a larger diameter cable.
8. If the voltage reading in step 6 was more than 1.0 VDC different from the base voltage reading:
a. Check the cable connections for tightness and corrosion.
b. If the cable is tight and not corroded, replace the cable with a larger diameter cable.
IMPORTANT: Resistance in the cables can cause a voltage drop and limit current to the starter. If corrosion is present, or if
the starter is worn, there may not be enough amperage to turn the starter motor.
NOTE: If the voltage at the starter is less than 11 VDC, the engine may not start.
9. Connect the FSM fuel pump harness connector to the engine harness.
90-8M0060785 DECEMBER 2011 Page 2B-3

Original Battery Cable Length and Gauge Shipped with Engine

Original Equipment Battery Cable Length/Wire Gauge Size Shipped with Engine
Models (HP) Cable Length Wire Gauge Size
6–25 (2 and 4‑Stroke 400 cc [24.4 in³] or less) 2.4 m (8 ft) 8
25–115 (except OptiMax) 2.4 m (8 ft) 6
125–250 (except OptiMax) 3.0 m (10 ft) 6
OptiMax/Verado 3.7 m (12 ft) 4
75/80/90/100/115 EFI FourStroke (2006 and newer) 3.7 m (12 ft) 4
Battery Cable Size for Outboard Models

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.
a a - Wire gauge size

b - Battery cable length
b
2758
Page 2B-4 90-8M0060785 DECEMBER 2011

Copper Battery Cable Wire Gauge Size

Wire Gauge Size Number SAE
6–25 hp (2 and OptiMax, Verado, 75–
25–115 hp (except 125–250 hp (except
Models 4‑Stroke 400 cc 115 EFI FourStroke
OptiMax) OptiMax)
[24.4 in³] or less) (2006 and newer)
2.4 m (8 ft) 8 6 ‑ ‑
2.7 m (9 ft) 6 4 ‑ ‑
3.0 m (10 ft) 6 4 6 ‑
3.4 m (11 ft) 6 4 4 ‑
3.7 m (12 ft) 6 4 4 4
4.0 m (13 ft) 6 2 4 2
4.3 m (14 ft) 4 2 4 2
4.6 m (15 ft) 4 2 4 2
4.9 m (16 ft) 4 2 2 2
5.2 m (17 ft) 4 2 2 2
5.5 m (18 ft) 4 2 2 2
5.8 m (19 ft) 4 2 2 2
6.1 m (20 ft) 4 2 2 2
6.4 m (21 ft) 2 1 2 1
6.7 m (22 ft) 2 1 2 1
7.0 m (23 ft) 2 1 2 1
Cable Length 7.3 m (24 ft) 2 1 2 1
7.6 m (25 ft) 2 1 2 1
7.9 m (26 ft) 2 1/0 1 1/0
8.2 m (27 ft) 2 1/0 1 1/0
8.5 m (28 ft) 2 1/0 1 1/0
8.8 m (29 ft) 2 1/0 1 1/0
9.1 m (30 ft) 2 1/0 1 1/0
9.4 m (31 ft) 2 1/0 1 1/0
9.8 m (32 ft) 2 1/0 1 1/0
10.1 m (33 ft) 2 2/0 1/0 2/0
10.4 m (34 ft) 2 2/0 1/0 2/0
10.7 m (35 ft) 1 2/0 1/0 2/0
11.0 m (36 ft) 1 2/0 1/0 2/0
11.3 m (37 ft) 1 2/0 1/0 2/0
11.6 m (38 ft) 1 2/0 1/0 2/0
11.9 m (39 ft) 1 2/0 1/0 2/0
12.2 m (40 ft) 1 2/0 1/0 2/0
90-8M0060785 DECEMBER 2011 Page 2B-5

Replacement Parts
! WARNING
IMPORTANT: Deep‑cycle batteries are not suitable for use as engine starting batteries or for use as accessory batteries that
are connected to high output engine charging systems. Deep‑cycle battery life may be shortened by high output engine
charging systems. Refer to individual battery manufacturer instructions for specific battery charging procedures and
applications.
Recommended Battery
A 12 volt marine battery with a minimum cold cranking amperage rating of 800 amperes or 1000 (minimum) marine cranking
amperes or 180 Ah (Amperes Hour) should be used.
Charging a Discharged Battery

! WARNING
An operating or charging battery produces gas that can ignite and explode, spraying out sulfuric acid, which can cause
severe burns. Ventilate the area around the battery and wear protective equipment when handling or servicing batteries.
The following basic rules apply to any battery charging situation:

1. Any battery may be charged at any rate (in amperes), or as long as spewing of electrolyte (from violent gassing) does not
occur, and for as long as electrolyte temperature does not exceed 52 °C (125 °F). If spewing of electrolyte occurs, or if
electrolyte temperature exceeds 52 °C (125 °F), charging rate (in amperes) must be reduced or temporarily halted to avoid
damage to the battery.
2. Battery is fully charged when, over a 2 hour period at a low charging rate (in amperes), all cells are gassing freely (not
spewing liquid electrolyte), and no change in specific gravity occurs. Full charge specific gravity is 1.260–1.275, corrected
for electrolyte temperature with electrolyte level at 4.8 mm (3/16 in.) over plate, unless electrolyte loss has occurred (from
age or overfilling), in which case, specific gravity reading will be lower. For most satisfactory charging, lower charging rates
in amperes are recommended.
3. If, after prolonged charging, specific gravity of at least 1.230 on all cells cannot be reached, battery is not in optimum
condition and will not provide optimum performance; however, it may continue to provide additional service, if it has
performed satisfactorily in the past.
4. To check the battery voltage while cranking the engine with an electric starting motor at ambient air temperature of 23.8 °C
(75 °F), place the red (+) lead of the tester on the positive (+) battery terminal and the black (–) lead of the tester on the
negative (–) battery terminal. If the voltage drops below 10‑1/2 volts while cranking, the battery is weak and should be
recharged or replaced.
Winter Storage of Batteries

Battery companies are not responsible for battery damage, either in winter storage or in dealer stock, if the following
instructions are not observed:
1. Remove battery from its installation as soon as possible and remove all grease, sulfate, and dirt from the top surface by
running water over top of the battery. Be sure, however, the vent caps are tight beforehand and blow off all excess water
thoroughly with compressed air. Check water level, making sure the plates are covered.
2. When adding distilled water to the battery, be extremely careful not to fill more than 4.8 mm (3/16 in.) above perforated
baffles inside the battery. Battery solution or electrolyte expands from heat caused by charging. Overfilling the battery will
cause the electrolyte to overflow (if filled beyond 4.8 mm [3/16 in.] above baffles).
3. 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.

4. If specific gravity drops below 1.240, check battery for reason and recharge. When gravity reaches 1.260, discontinue
charging. To check specific gravity, use a hydrometer, which can be purchased locally.
Page 2B-6 90-8M0060785 DECEMBER 2011

5. Repeat preceding charging procedure every 30–45 days, as long as the battery is in storage, for best possible
maintenance during inactive periods to ensure a good serviceable battery in spring. When ready to place the battery back
in service, remove excess grease from the terminals (a small amount is desirable on terminals at all times), recharge
again, as necessary, and reinstall the battery.
Alternator System
System Components
The charging system consists of the alternator, battery, 100 amp fusible link, main power relay, and wiring that connects these
components.
g
d
f e
48983
a- Alternator
b- Main power relay
c- Starter solenoid
d- To battery
e- Bullet connector
f- Power stud
g- 100 amp fusible link
Precautions
The following precautions must be observed when working on the alternator system. Failure to observe these precautions may
result in serious damage to the alternator system.
1. Do not attempt to polarize the alternator.
2. Do not short across or ground any of the terminals on the alternator except when specifically instructed.
3. Never disconnect the alternator output lead, regulator harness, or battery cables when the alternator is being driven by the
engine.
4. Always remove the negative (–) battery cable from the battery before working on the alternator system.
5. When installing the battery, be sure to connect the negative (–) (grounded) battery cable to the negative (–) battery
terminal, and the positive (+) battery cable to the positive (+) battery terminal. Connecting the battery cables to the battery
in reverse will result in blowing the 100 amp fusible link in the output lead of the alternator.
90-8M0060785 DECEMBER 2011 Page 2B-7

6. When using a charger or booster battery, connect it in parallel with the existing battery (positive to positive; negative to
negative).
Alternator Description
The alternator employs a rotor that is supported in two end frames by ball bearings, and is driven at 2.8 times engine speed.
The rotor contains a field winding enclosed between two multiple‑finger pole pieces. The ends of the field winding are
connected to two brushes which make continuous sliding contact with the slip rings. The current (flowing through the field
winding) creates a magnetic field that causes the adjacent fingers of the pole pieces to become alternate north and south
magnetic poles.
The 3‑phase stator is mounted directly over the rotor pole pieces and between the two end frames. It consists of three windings
wound 120 degrees electrically out of phase on the inside of a laminated core.
The rectifier bridge contains six diodes which allows current to flow from the ground, through the stator, and to the output
terminal, but not in the opposite direction.
When current is supplied to the rotor field winding and the rotor is turned, the movement of the magnetic fields created induces
an alternating current into the stator windings. The rectifier bridge changes this alternating current to direct current which
appears at the output terminal. The diode trio is connected to the stator windings to supply current to the regulator and the rotor
field during operation.
Voltage output of the alternator is controlled by a transistorized voltage regulator that senses the voltage at the battery, and
regulates the field current to maintain alternator voltage for properly charging the battery. Current output of the alternator does
not require regulation, as maximum current output is self‑limited by the design of the alternator. As long as the voltage is
regulated within the prescribed limits, the alternator cannot produce excessive current. A cutout relay in the voltage regulator
also is not required, as the rectifier diodes prevent the battery from discharging back through the stator.
A small amount of current is supplied by the excitation circuit in the regulator to the rotor field to initially start the alternator
charging. Once the alternator begins to produce output, field current is supplied solely by the diode trio.
The alternator is equipped with two fans which induce air flow through the alternator to remove heat created by the rectifier and
stator.
Diagnosis of Alternator System on the Engine

1. If the battery is undercharged, verify the condition is not caused by excessive accessory current draw or by accessories
which have been accidentally left on.
2. Check the physical condition and the state of the battery charge. The battery must be 75% (1.230 specific gravity) or
greater to obtain valid results in the following tests. Charge the battery if it does not show the minimum 75% state of
charge.
3. Inspect the entire alternator system wiring for defects. Check all connections for tightness and cleanliness, particularly the
battery cable clamps and battery terminals.
4. The alternator mounting bracket has rubber isolation mounts. Ensure the alternator ground cable is secured to the
alternator and the cylinder block.
IMPORTANT: The red fusible link cable on the alternator must be tight. A discolored insulator sleeve indicates the lead
was loose and becoming hot. Verify the fusible link cable attaching locknut is torqued to specification.
a - Insulator boot (fusible link)

b - Alternator sense connector
b
48080

Nut securing fusible link to alternator 4.5 39.8
Page 2B-8 90-8M0060785 DECEMBER 2011

5. Check the belt for excessive wear, cracks, glazed surfaces, and fraying. Belt tension is maintained by the belt which is a
stretch to fit application. Verify the mounting screws are tight.
b a - Front mounting screw

b - Rear mounting screw
a
48145
6. The 100 amp fusible link is located behind the electrical cover on the port side of the engine. If the fusible link is blown,
check the battery leads for reversed polarity connection before replacing the fusible link.
48719
Alternator System Circuitry Test

1. Check the belt condition and tension. The belt is a stretch to fit application. If there are signs of the belt slipping, replace
the belt.
2. Check the wire connections at the alternator for tightness and corrosion.
3. Verify the alternator grounded to the cylinder block does not have high resistance. The grounding of the alternator is
through the alternator mounting screws. Check the alternator mounting screws for tightness and corrosion.
4. Check the wire connections at the battery for tightness and corrosion.
5. Check the battery condition. The battery should be fully charged.
Output Circuit
Perform the following tests with a DMT 2004 digital multimeter to ensure the circuits between the alternator and all components
within the charging system are in good condition.
1. Connect the DMT positive (+) lead to the positive (+) battery terminal.
2. Connect the DMT negative (–) lead to the negative (–) battery terminal.
3. Supply cooling water to the engine.
4. Start the engine and increase the engine speed to 1300 RPM.
5. Observe the voltage reading.
6. If the reading is between 13.5 and 14.8 volts, switch the DMT to the AC volt position. A reading of 0.25 AC volts or less
indicates the alternator diodes are functional. A reading above 0.25 AC volts indicates the diodes are faulty and the
alternator must be replaced.
90-8M0060785 DECEMBER 2011 Page 2B-9

NOTE: A voltage reading between 13.5 and 14.8 volts are for starting systems without a battery isolator installed. A battery
isolator will have a parasitic voltage drop and the alternator will compensate for the voltage drop. The output voltage may
be as high as 19 volts.
A very high voltage level measured at the output terminal of the alternator may be an indication of an open circuit between
the output terminal and the battery. A blown fusible link is the most likely cause for an open circuit.
The reason for the high voltage reading is the alternator sense circuit is indicating reduced battery voltage and causes the
alternator to increase voltage output due to the blown fusible link. The voltage output could be as high as 27 volts. This
higher voltage is sometimes interpreted as a failed regulator and the complete alternator is mistakenly replaced.
7. If the reading is below 13.5 volts:
a. Connect the positive (+) DMT lead to the alternator output stud.
b. Connect the negative (–) DMT lead to a ground on the alternator.
c. Wiggle the engine wiring harness while observing the voltmeter. The meter should indicate the approximate battery
voltage and should not vary. If no reading is obtained or if the reading varies, inspect the wiring harness for loose
connections, corrosion, breaks, or shorts. Repair or replace the harness as required.
8. If the reading is above 15 volts at the battery without a battery isolator installed, the alternator is overcharging and must be
replaced.
a - Alternator output stud

b - Alternator ground
a
48720
Sensing Circuit
1. Unplug the red and red/white excitation/sensing wire connector from the alternator.
2. Connect the positive (+) DMT lead to the red pin and the negative (–) DMT lead to the alternator ground.
3. The DMT should indicate the battery voltage. If battery voltage is not present, check the red lead for a loose or dirty
connection, or damaged wiring.
NOTE: This circuit has an in‑line bullet connector for installing an isolator accessory. If no voltage is present, verify the
bullet connector is intact and not damaged or burnt. The bullet connector is behind the electrical cover.
a - Sensing circuit red lead

48721
Excitation Circuit
IMPORTANT: The following test for battery voltage is only possible when the main power relay is engaged. The main power
relay is only engaged for a few seconds after the key is turned to the "ON" position.
1. Unplug the red and red/white excitation/sensing wire connector from the alternator.
Page 2B-10 90-8M0060785 DECEMBER 2011

2. Connect the positive (+) DMT lead to the red/white pin and the negative (–) DMT lead to the alternator ground.
3. Turn the ignition key to the "ON" position. The DMT should indicate battery voltage. If battery voltage is not present, check
the purple lead for a loose or dirty connection, damaged wiring, or a malfunctioning main power relay.
a - Excitation circuit red/white

48722
Alternator Removal
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected motor starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing motor components.
1. Disconnect the battery cables from the batteries.

2. Pull the insulator boot off the alternator output wire.
3. Remove the nut securing the alternator output wire and remove the wire from the alternator.
4. Remove the engine harness alternator sense connector from the alternator.

b
48080
5. Loosen the front alternator screw.
90-8M0060785 DECEMBER 2011 Page 2B-11

6. Remove the rear alternator screw.
b a - Front alternator screw

b - Rear alternator screw
48081
48137
8. Remove the alternator belt.
48138
Page 2B-12 90-8M0060785 DECEMBER 2011

9. Remove the front screw and the alternator.
48140
Alternator Installation
1. Install the alternator onto the cylinder block. Secure the alternator with a M10 x 60 screw. Do not tighten the screw at this
point.
48140
48141
90-8M0060785 DECEMBER 2011 Page 2B-13

3. Push the alternator towards the rear of the engine.
48143
4. Install the rear alternator M10 x 60 screw and tighten to the specified torque.
5. Tighten the front alternator screw to the specified torque.
b a - Front alternator screw

b - Rear alternator screw
48081

Front and rear alternator screws (M10 x 60) 50 36.8
6. Connect the engine harness alternator sense connector into the alternator.
7. Install the fusible link to the alternator and secure with a nut. Tighten the nut to the specified torque.
8. Apply Liquid Neoprene to the alternator output wire connection to prevent corrosion and allow to dry.
Page 2B-14 90-8M0060785 DECEMBER 2011

9. Pull the insulator boot over the alternator output wire connection.

b
48080


25 Liquid Neoprene Alternator output wire connection 92- 25711 3
10. Connect the battery cables to the batteries.
Starter System
Starter Motor Amp Draw
Starter Motor
No load amp draw 50–70 A
Normal amp draw 150–225 A
Starter System Description

The battery supplies voltage to activate the starter motor from the starter solenoid. When the ignition key switch is turned to the
"START" position, the ECM completes the ground circuit for the start relay. The start relay becomes engaged, closes the switch
in the relay, and transfers fused 12 volts to energize the starter solenoid. The solenoid plunger closes the high current contacts,
transfers battery voltage to the starter motor brushes which enable the starter motor to rotate the engine to initiate the intake,
compression, combustion, and exhaust sequence. The starter motor is capable of rotating the engine 320 RPMs.
There are two starter solenoid coil windings. The first starter solenoid coil winding pulls the starter solenoid plunger in,
engaging the gear/clutch assembly into the flywheel ring gear. The first coil winding may draw up to 30 amps at 12.6 volts when
activated. When the starter solenoid plunger is completely pulled into the starter solenoid, the first starter solenoid coil winding
is disconnected. The second starter solenoid coil winding is then activated to hold the starter solenoid plunger in, completing
the circuit to transfer battery voltage to the starter motor brushes. The second starter solenoid coil winding may draw up to 10
amps at 12.6 volts when activated.
The neutral start switch opens the key switch start circuit when the shift control lever is not in neutral, preventing accidental
starting when the engine is in gear. Engaging the starter circuit while the engine is running in neutral will turn the engine off.
Starting System Components

• Battery
• Ignition switch
• Neutral start switch
• Starter solenoid
• Starter motor
• Main power relay
• Starter relay
• Power stud
90-8M0060785 DECEMBER 2011 Page 2B-15

Starter Circuit Troubleshooting

Before Troubleshooting the Starter Circuit
Before troubleshooting the starter circuit, verify the following conditions:
1. Confirm the battery is fully charged.
2. Ensure the remote control lever is in neutral (if applicable).
3. Ensure the tiller handle shift control is in neutral (if applicable).
4. Check all power and ground terminals for corrosion or loose connections.
5. Check all cables and wiring for frayed or worn insulation.
6. Check all of the fuses related to the operation of the engine.
IMPORTANT: The starting of this engine is controlled by the ECM. The main power relay and the starter relay should be
checked with the CDS G3 Diagnostic Interface tool prior to troubleshooting the starter, key switch, and harnesses. Use the
shunt tool to eliminate the boat harness and key switch when testing the main power relay and starter relay.

8M0046124
Harness
12 Volt Shunt Tool 91‑889675A01
Starter Circuit Troubleshooting Chart

Use the DMT 2004 digital multimeter or an equivalent auto range digital meter for all of the tests.
Some of the tests require the battery voltage be removed from the starter solenoid to prevent unexpected engine cranking.
The following starter circuit troubleshooting chart will assist in locating any malfunction in the starting circuitry. Do not skip any
of the testing sequence procedures unless advised to do so.
Page 2B-16 90-8M0060785 DECEMBER 2011

48841
j
k
3
l
1
5
h
2
87
g
f
d
e
c
m
b
a
67
70
68
69
51
66
50
34
33
18
1
17
a- ECM connector
b- Main power relay
c- Starter relay
d- 2 amp fuse
e- 20 amp fuse
f- 20 amp fuse
g- 15 amp fuse
90-8M0060785 DECEMBER 2011 Page 2B-17

h- Starter solenoid
i- Power stud
j- Key switch
k- Neutral start switch (tiller handle or remote control)
l- 14 pin connector
m- Battery
Starter Motor Does Not Turn

Test Number Procedure Test Results
Set the meter to read voltage, auto range. Battery voltage should be 12.6 volts or higher. Battery voltage
Measure the voltage between the starting less than 12.6 volts: check the condition of the battery and load
battery terminals. test the battery.
Voltage reading should be the same as the battery. Voltage
reading less than the battery:
Measure the battery voltage between test • Ensure the battery positive and negative cables are the
point 1 (starter solenoid battery power cable) correct wire gauge for the cable length.
and test point 2 (common powerhead • Ensure the battery cable connections are tight on the battery
ground). and on the powerhead.
• Ensure the battery cables are not corroded.
Test 1
Voltage reading should be the same as test point 1. Voltage
reading less than test point 1:
Measure the battery voltage between test
point 3 (power stud) and test point 2 • Ensure the nuts are torqued to specifications at test points 1
(common powerhead ground). and 3.
• Ensure the cable connection is not corroded.
Voltage reading should be the same as test point 1. Voltage

Measure the battery voltage between test
reading less than test point 1:
point 8 (ECM and engine sensor ground) and
test point 1 (starter solenoid battery power • Ensure the cable connection is not corroded.
cable). • Ensure all fasteners are tight.
Disconnect the crankshaft position sensor for test 2. This will prevent the engine from starting and set a failure code. The code
should be erased with the CDS G3 Diagnostic Interface tool after the troubleshooting procedure is completed.
Battery voltage is indicated and the starter solenoid clicks. Check
the battery voltage at test point 1.
• Battery voltage is greater than 9.5 volts ‑ the starter motor is
defective.
Check for battery voltage at test point 4
between the starter solenoid yellow/red wire • Battery voltage is less than 9.5 volts ‑ the starter solenoid is
Test 2 terminal and test point 2 (common defective.
powerhead ground). Turn the key switch to
the "START" position. Battery voltage is indicated and the starter solenoid does not
click. Check the starter solenoid pull in coil resistance.
• Refer to: Starter Will Not Stay Engaged (Chatter) Test 1.
No battery voltage indicated ‑ proceed to Test 3.

No continuity ‑ There is an open circuit between the battery
negative post and the common powerhead ground.
Set the meter to read ohms, auto scale.
• Check for a loose or corroded battery negative cable
Connect the meter at test point 2, between
Test 3 connection at the powerhead and the battery.
the common powerhead ground and the
battery negative post. • Check for an open battery negative cable.
Continuity indicated ‑ proceed to Test 4.
Page 2B-18 90-8M0060785 DECEMBER 2011

Starter Motor Does Not Turn

No continuity:
• Key switch is failed or the harness has an open circuit.
• Disconnect the key switch at test point 6 and test the key
switch "ON" circuit for continuity between the red and purple
Disconnect the 14 pin connector at test point wires. No continuity: the key switch is failed. Continuity
5. Set the meter to read ohms, auto scale. indicated: Check the boat harness "A" and "C" pins for
Test 4 Connect the meter to pins "A" and "C" on the continuity. Replace or repair the boat harness if no continuity
boat harness 14 pin connector, key switch is found.
end. Turn the key switch to the "ON" position.
Continuity indicated:
• Turn the key switch to the "START" position. No continuity:
the key switch is failed.
• Continuity indicated: proceed to Test 5.
No continuity:
• The yellow/red wire is open: the neutral start switch is failed/
open or the key switch has failed.
• Move the shift control in and out of gear: intermittent
continuity, the neutral safety switch is failed.
Connect the meter to pin "C" and pin "N."
Test 5 • Disconnect the key switch at test point 6 and check for
Turn the key switch to the "START" position.
continuity between the yellow/red wire and the purple wire on
the key switch. Turn the key switch to the "START" position:
no continuity, the key switch is failed.
• Continuity indicated: Proceed to Starter Will Not Stay
Engaged (Chatter).
Starter Will Not Stay Engaged (Chatter)

Starter solenoid hold‑in coil resistance is 0.8 Ω ±
10%.
Disconnect the yellow/red exciter wire from the starter • Starter solenoid hold‑in coil is good. Proceed
solenoid at test point 4. Measure the resistance between the to Test 2.
Test 1
exciter terminal of the starter solenoid and the starter
solenoid metal housing. Starter solenoid hold‑in coil resistance is in
excess of 0.8 Ω ± 10% or open.
• Starter solenoid hold‑in coil is defective.
Starter solenoid pull‑in coil resistance is 0.2 Ω ±

10%.
Remove the starter motor brush lead from the starter • Starter solenoid pull‑in coil is good.
solenoid at test point 7. Measure the resistance between the • Ensure battery is fully charged.
Test 2
exciter terminal of the starter solenoid and the starter
solenoid brush lead terminal. Starter solenoid pull‑in coil resistance is in
excess of 0.2 Ω ± 10% or open.
• Starter solenoid pull‑in coil is defective.
Starter Removal
! WARNING
90-8M0060785 DECEMBER 2011 Page 2B-19

2. Remove the screw securing the cylinder block ground wire in the starter housing.
3. Remove the screw securing the battery negative cable to the starter housing.
a - Screw securing the cylinder block ground wire

b - Screw securing the battery negative cable
b
48122
4. Pull the insulator boot off the starter solenoid power stud and remove the nut securing the battery cable to the starter
solenoid power stud. Remove the battery positive cable.
5. Remove the nut and washer securing the starter exciter wire to the starter solenoid. Remove the exciter wire.
a - Nut and washer securing the starter exciter wire

b - Nut securing the battery cable
48123
6. Remove the three bolts securing the starter to the cylinder block.
a - M10 x 60 flange head screw (2)

b - M10 x 45 flange head screw
48127
Page 2B-20 90-8M0060785 DECEMBER 2011

Starter Installation
1. Install the starter onto the cylinder block and secure with two M10 x 60 and one M10 x 45 screw. Each screw must have a
washer. Tighten the screws to the specified torque.
a - M10 x 60 flange head screw (2)

48127

Starter mounting screws (M10 x 60 [2], M10 x 45 [1]) 21 185.8
2. Install the starter exciter wire to the starter solenoid and secure with a nut and washer. Tighten the nut to the specified
torque.
3. Install the battery positive cable to the starter solenoid power stud and secure with a nut. Tighten the nut to the specified
torque.
4. Apply Liquid Neoprene to the power connections to prevent corrosion and allow to dry.
5. Pull the insulator boot onto the starter solenoid power stud.
a - Nut and washer securing the starter exciter wire

b - Nut securing the battery cable
48123

Nut securing the starter exciter wire 2.5 22
Nut securing the battery cable to the starter 9 79.6

25 Liquid Neoprene Starter solenoid power connections 92- 25711 3
6. Secure the battery negative cable to the starter housing with a M8 x 20 screw. Tighten the screw to the specified torque.
7. Secure the cylinder block ground wire to the starter housing with a M6 x 25 screw. Tighten the screw to the specified
torque.
90-8M0060785 DECEMBER 2011 Page 2B-21

8. Apply Liquid Neoprene to the ground wire connections to prevent corrosion.
a - Screw securing the cylinder block ground wire

b - Screw securing the battery negative cable
b
48122

Screw securing the battery negative cable (M8 x 20) 17 150.4
Screw securing the cylinder block ground wire (M6 x 25) 10 88.5

25 Liquid Neoprene Ground wire connections 92- 25711 3
Key Switch Test (Four Position)

1. Disconnect the key switch from the command module harness.
2. Set ohmmeter on R x 1 scale for the following tests.
3. If meter readings are other than specified in the following tests, verify that the switch and not the wiring is faulty. If the
wiring checks OK, replace the switch.
a- Pin A ‑ Red
b- Pin B ‑ Black
c- Pin C ‑ Purple/white
d- Pin D ‑ Purple
e- Pin E ‑ Black/yellow
f- Pin F ‑ Yellow/red
c b a
d e f 3887
Page 2B-22 90-8M0060785 DECEMBER 2011

Key Position Continuity should be indicated at the following points:

Off B E
Accessories A C
Run A D
A F
Start F D
A D
90-8M0060785 DECEMBER 2011 Page 2B-23

Notes:
Page 2B-24 90-8M0060785 DECEMBER 2011

Timing, Synchronizing, and Adjustments
Electrical
Section 2C - Timing, Synchronizing, and Adjustments
Table of Contents 2
C
Idle Timing Adjustment (All Models).................................. 2C-2 Throttle Link Removal ................................................2C-3
Maximum Timing Adjustment (All Models)........................ 2C-2 Throttle Link Installation..............................................2C-4
Throttle Link....................................................................... 2C-3
90-8M0060785 DECEMBER 2011 Page 2C-1


Throttle link actuator shoulder screw threads
66 Loctite 242 Threadlocker 92-809821
Throttle lever shoulder screw threads
Throttle link actuator shoulder screw and washers
95 2-4-C with PTFE 92-802859A 1
Throttle lever shoulder screw and washers
Special Tools
8M0046124
Harness
41993
Idle Timing Adjustment (All Models)

Idle timing is not adjustable. Idle timing is controlled by the PCM/ECM. Idle timing can be monitored with the CDS G3
Diagnostic Interface tool.

8M0046124
Harness
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
CDS G3 Diagnostic Interface tool.

8M0046124
Harness
Page 2C-2 90-8M0060785 DECEMBER 2011

Throttle Link
Throttle Link Removal
1. Remove the screw securing the throttle lever to the intake manifold.
e
b
a
f
d
c
48202
a- Shoulder screw
b- Wave washer
c- Washer
d- Throttle lever
e- Return spring
f- Washer
2. Disconnect the throttle link from the throttle body lever.
48203
3. Remove the screw securing the throttle link actuator to the intake manifold.
90-8M0060785 DECEMBER 2011 Page 2C-3

4. Remove the throttle link rod actuator assembly from behind the intake manifold.
c
a b
d e
48206
a- Shoulder screw
b- Wave washer
c- Washer
d- Throttle link actuator
e- Washer
Throttle Link Installation

1. Measure the link rod length. Adjust if necessary.
a
48704
a - 415.1 mm (16.34 in.)
2. Install the throttle link rod onto the throttle link actuator.
3. Install the wave washer onto the throttle link actuator shoulder screw.
4. Install the washer onto the throttle link actuator shoulder screw.
5. Lubricate the washers and the shoulder of the screw with 2‑4‑C with PTFE. Do not allow the lubricant onto the shoulder
screw threads.
6. Insert the shoulder screw with the washers through the throttle link actuator.
Page 2C-4 90-8M0060785 DECEMBER 2011

7. Install the washer onto the shoulder screw threaded end.
a- Shoulder screw
b- Wave washer
f c- Washer
e d- Throttle link actuator
e- Throttle link rod
f- Washer
d
b
48207
a

95 2-4-C with PTFE Throttle link actuator shoulder screw and washers 92-802859A 1
8. Apply Loctite 242 Threadlocker to the threads of the shoulder screw.

66 Loctite 242 Threadlocker Throttle link actuator shoulder screw threads 92-809821
9. Guide the throttle link rod behind the intake manifold and secure the throttle link actuator to the intake manifold. Tighten the
shoulder screw to the specified torque.
a a - Throttle link rod

b - Shoulder screw
48208

Shoulder screw 10 88.5
90-8M0060785 DECEMBER 2011 Page 2C-5

10. Connect the throttle link to the throttle body lever.
48203
11. Install the return spring into the throttle lever.
a - Long end
b - Short end
a b
48210
12. Install the wave washer onto the throttle lever shoulder screw.
13. Install the washer onto the throttle lever shoulder screw.
screw threads.
15. Insert the shoulder screw with the washers through the throttle lever.
a- Shoulder screw
e b- Wave washer
c- Washer
d- Throttle lever
e- Washer
d
c
b
a 48211

95 2-4-C with PTFE Throttle lever shoulder screw and washers 92-802859A 1
Page 2C-6 90-8M0060785 DECEMBER 2011


66 Loctite 242 Threadlocker Throttle lever shoulder screw threads 92-809821
17. Verify the throttle actuator roller is engaged with the throttle lever.
18. Align the long end of the spring with the boss on the intake manifold.
19. Secure the throttle lever to the intake manifold block with the shoulder screw. Tighten the shoulder screw to the specified
torque.
a - Throttle actuator roller

b b - Long end of the spring
c - Shoulder screw
c
48212

90-8M0060785 DECEMBER 2011 Page 2C-7

Notes:
Page 2C-8 90-8M0060785 DECEMBER 2011

Accessory Wire Diagrams
Electrical
Section 2D - Accessory Wire Diagrams
Table of Contents 2
D
Boat Sensor....................................................................... 2D-2 Digital Speedometer Harness Test.............................2D-3
Boat Sensor Harness Test......................................... 2D-2 Digital Block Water Pressure (Optional Sensor)................2D-5
Digital Speedometer (Optional Sensor) ............................ 2D-3
90-8M0060785 DECEMBER 2011 Page 2D-1

Special Tools

V Hz
H z TEMP
mA
A
mV IG
OFF IP
TEMP
A mA COM V Hz
4516
Boat Sensor
The boat sensor harness connector is a junction location for sensors external of the engine operations. These external sensors
may include: depth, paddle wheel for low speeds, seawater temperature, fuel, and water levels and is most useful when
incorporating SmartCraft gauges, GPS, and chart plotter technologies.
Boat Sensor Harness Test

1. Disconnect the vessel harness from the engine harness boat sensor connector.
2. Perform a visual inspection of the engine harness boat sensor connector pins and the wires coming from the connector.
Look for broken, bent, or corroded pins.
3. Disconnect the engine harness from the ECM.
4. Use the DMT 2004 digital multimeter to perform an ohm check of the wiring between the engine harness boat sensor
connector and the ECM connector.
NOTE: All accessory sensor ground wires are 5 volts negative. They are spliced together and connect to the ECM at pin
10. All accessory sensor power wires are 5 volts positive. They are spliced together and connect to the ECM at pin 51.
Unless there are multiple sensor failures, the most likely failure would be at the splice point, connector, or between the
connector and the splice point.
a
1 18 34 51
67
68
GRY/DK BLU
b
69
70
17 33 50 66
48967
a - ECM connector
b - Boat sensor connector
Meter Test Leads

Red Black
Pin 7 Sensor connector C (tan/purple) Auto Less than 1
Pin 10 Sensor connector A (black/green) Auto Less than 1
Pin 15 Sensor connector D (gray/dark blue) Auto Less than 1
Pin 38 Sensor connector E (tan/orange) Auto Less than 1
Pin 40 Sensor connector F (pink/black) Auto Less than 1
Page 2D-2 90-8M0060785 DECEMBER 2011

Meter Test Leads

Red Black
Pin 51 Sensor connector B (purple/black) Auto Less than 1
Digital Speedometer (Optional Sensor)

The digital speedometer sensor harness connector is used to connect a digital water pressure (speed) sensor. The digital
speedometer sensor is most useful when incorporating SmartCraft gauges, GPS, and chart plotter technologies.
a - Speedometer hose
b
b - Electrical cover
c - Digital speedometer
a sensor
d - Engine harness
connector
c d
49492
Digital Speedometer Harness Test

1. Disconnect the speedometer sensor harness from the engine harness digital speedometer sensor connector.
2. Perform a visual inspection of the engine harness digital speedometer sensor connector pins and the wires coming from
the connector. Look for broken, bent, or corroded pins.
90-8M0060785 DECEMBER 2011 Page 2D-3

NOTE: All accessory sensor ground wires are 5 volts negative. They are spliced together and connect to the ECM at pin
10. All accessory sensor power wires are 5 volts positive. They are spliced together and connect to the ECM at pin 51.
Unless there are multiple sensor failures, the most likely failure would be at the splice point, connector, or between the
connector and the splice point.
d a- ECM connector
b- Speedometer sensor connector
c- Pin 1 (black/green)
c d- Pin 3 (white/orange)
e e- Pin 2 (purple/black)
b
1 18 34 51
67
a
68
69
70
66 48930
17 33 50
Meter Test Leads

Red Black
Pin 10 Sensor connector 1 (black/green) Auto Less than 1
Pin 36 Sensor connector 3 (white/orange) Auto Less than 1
Pin 51 Sensor connector 2 (purple/black) Auto Less than 1
Page 2D-4 90-8M0060785 DECEMBER 2011

Digital Block Water Pressure (Optional Sensor)

The digital block water pressure sensor harness connector is used to connect a digital block water pressure sensor. The digital
block water pressure sensor is most useful when incorporating SmartCraft gauges or other technologies that use a control area
network (CAN) communications protocol.

b - Digital block water pressure
sensor
a c - Exhaust manifold
49494
1. Disconnect the digital block water pressure sensor from the engine harness digital block water pressure sensor connector.
2. Perform a visual inspection of the engine harness digital block water pressure sensor connector pins and the wires coming
from the connector. Look for broken, bent, or corroded pins.
NOTE: All engine sensor ground wires are 5 volts negative. They are spliced together and connect to the ECM at pin 42.
All accessory sensor power wires are 5 volts positive. They are spliced together and connect to the ECM at pin 34. Unless
there are multiple sensor failures, the most likely failure would be at the splice point, connector, or between the connector
and the splice point.
d a - ECM connector
b - Digital block water pressure sensor
connector
c - Pin 1 (black/orange)
e d - Pin 3 (white/green)
c e - Pin 2 (purple/yellow)
b
1 18 34 51 a
67
68
69
70
17 33 50 66
48937
90-8M0060785 DECEMBER 2011 Page 2D-5

Meter Test Leads

Red Black
Pin 34 Sensor connector 2 (purple/yellow) Auto Less than 1
Pin 35 Sensor connector 3 (white/green) Auto Less than 1
Pin 42 Sensor connector 1 (black/orange) Auto Less than 1
Page 2D-6 90-8M0060785 DECEMBER 2011

Theory of Operation
Fuel System
Section 3A - Theory of Operation
Table of Contents
3
Fuel Supply Components...................................................3A-4 Engine Control Module (ECM)..................................3A-11
Fuel Supply Module Components .....................................3A-6 Throttle Body............................................................ 3A-11
Integrated Air Fuel Module and Fuel Rail Components..... 3A-6 Idle Air Control (IAC).................................................3A-12
Intake Manifold Components............................................. 3A-8
Air Induction System........................................................ 3A-10
Fuel Supply Module (FSM)....................................... 3A-12
Fuel Lift Pump...........................................................3A-13
A
Fuel Injection System.......................................................3A-10 High‑Pressure Fuel Pump........................................ 3A-14
Air Induction and Fuel Injection System...........................3A-10 Fuel Pressure Regulator...........................................3A-14
Fuel System Description...........................................3A-10 Fuel Injector.............................................................. 3A-15
Main Power Relay (MPR)......................................... 3A-11 Guardian Protection System............................................ 3A-15
Intake Manifold......................................................... 3A-11 Fuel Flow Diagram...........................................................3A-16
90-8M0060785 DECEMBER 2011 Page 3A-1

Theory of Operation
Special Tools
8M0046124
Harness
41993
Page 3A-2 90-8M0060785 DECEMBER 2011

Theory of Operation
Notes:
90-8M0060785 DECEMBER 2011 Page 3A-3

Theory of Operation
Fuel Supply Components
1 6 2
7
3
6
8
4
5
4
3
2
10
11
20
12
19
13
16
14
15
48995
17
18
Page 3A-4 90-8M0060785 DECEMBER 2011

Theory of Operation
Fuel Supply Components

Torque
1 1 Manifold reference hose
2 2 Metal clamp (15.7 mm)
3 2 Hose
5 1 Fuel filter
6 2 Cable tie
7 1 Static sleeve
8 1 Hose
9 1 Fuel filter retainer
10 1 O‑ring
11 1 Grommet
12 1 Fuel supply module
13 1 Bushing
14 1 Grommet
15 1 Washer
16 1 Screw (M6 x 25) 10 88.5
17 1 Hose retainer
18 1 Plastic screw
19 1 Hose
20 1 Fuel filter
90-8M0060785 DECEMBER 2011 Page 3A-5

Theory of Operation
Fuel Supply Module Components

Integrated Air Fuel Module and Fuel Rail Components
1
2
4
3
5
6
48997
Page 3A-6 90-8M0060785 DECEMBER 2011

Theory of Operation
Integrated Air Fuel Module and Fuel Rail Components

Torque
1 1 Vent hose assembly
2 4 Fuel injector
3 4 Fuel injector retainer
4 1 Fuel rail
5 4 Screw (M6 x 20) 8 70.8
6 2 Screw (M4 x 16) 1.7 15
90-8M0060785 DECEMBER 2011 Page 3A-7

Theory of Operation
Intake Manifold Components

1
5
6
4
8
9
23
22 1
12
11
17
16 20
10 15
21 3
18
13 14
20
19
17
16
15 49355
Page 3A-8 90-8M0060785 DECEMBER 2011

Theory of Operation

Torque
1 6 Screw (M6 x 20) 8 70.8
2 1 Throttle body assembly
3 1 Intake manifold
4 4 Seal
5 1 Seal
6 1 Link rod
7 1 Socket
8 5 Retainer
9 11 Screw (M6 x 40) 10 88.5
10 1 Screw (M4 x 16) 6 53.1
11 1 Bracket
12 1 Manifold absolute pressure sensor
13 1 Plastic screw
14 1 Clip
15 2 Shoulder screw 10 88.5
16 2 Wave washer
17 2 Washer
18 1 Throttle lever
19 1 Return spring
20 2 Washer
21 1 Throttle link actuator
22 1 Link rod retainer
23 1 Idle air control
90-8M0060785 DECEMBER 2011 Page 3A-9

Theory of Operation
Air Induction System

The air volume entering the engine at idle is controlled by the idle air control (IAC) which is modulated by the engine control
module (ECM). The duty cycle of the modulation is dependent on the throttle position sensor (TPS) value, manifold absolute
pressure (MAP) sensor, air temperature values, and engine RPM.
The IAC is operated with an electric solenoid. The position of the IAC is determined by the ECM. The ECM supplies voltage to
open the IAC during engine operation.
The intake manifold runners allow the air to flow smoothly to the combustion chamber. Each runner has a single fuel injector
controlled by the ECM. The fuel injector has an orifice plate which contains small holes. The orifice plate design allows for a
better atomization of the fuel with the air. The injectors spray the fuel directly at the intake valves.
Fuel Injection System

The fuel injection system is a synchronous (batch timed) multiport injection. The fuel delivery system in conjunction with the
ignition system, is controlled by the engine control module (ECM). The ECM requires input information from multiple sensors to
maintain optimum fuel injection volume (pulse width) and fuel injection timing. The ECM uses information received from the
various sensors to adjust the idle air control (IAC) during engine idle operations, fuel injection timing/volume, and the amount of
engine timing. The ECM indirectly applies 12 volts to the fuel lift pump and high‑pressure fuel pump through the main power
relay, completing the ground circuit through the ECM.
Fuel pressure changes with engine demands. When the engine is under low or high demands, the manifold absolute pressure
changes. The demands of the engine are known to the ECM through the manifold absolute pressure (MAP) sensor digital
signal change and the throttle position sensor. Fuel pressure will change in conjunction with the manifold absolute pressure
change. A hose on the intake manifold is connected to the fuel pressure regulator inside the fuel supply module (FSM). The
manifold pressure changes will push or pull the fuel pressure regulator diaphragm, changing the amount of fuel pressure in the
fuel rail. The excessive fuel pressure is released inside the FSM.
Fuel injection volume is initially charted in the ECM when the system is activated by turning the key to the "ON" position. The
ECM reads the MAP sensor in the intake manifold to determine the ambient barometric (BARO) pressure. The ECM then looks
at the cylinder block coolant temperature and manifold air temperature. The BARO pressure, cylinder block coolant
temperature, and air temperature readings are the base for all fueling strategies at start‑up. Fuel strategy changes constantly
during engine operation.
The fuel is water‑cooled. While the engine is running, water is pumped up to the powerhead by the water pump located in the
lower unit. Water is pumped up to the engine through a tube that conjoins with the exhaust tube water jacket located on the port
side of the driveshaft housing. A filter on the exhaust tube water jacket allows some of the water to be diverted to the FSM. The
water enters the FSM and passes through two metal tubes and exits outside the FSM to the driveshaft housing.
Air Induction and Fuel Injection System

Fuel System Description
The components of the fuel system are:
• Main power relay (MPR)
• Intake manifold
• Engine control module (ECM)
• Throttle body
• Idle air control (IAC)
• Fuel supply module (FSM)
• Fuel lift pump
• High‑pressure fuel pump
• Fuel pressure regulator
• Fuel cooler
• Fuel injector
IMPORTANT: An external electric fuel pump is not allowed by the U.S. Coast Guard.
NOTE: This particular fuel system does not require an external primer bulb although one can be used for priming the fuel
delivery system.
Page 3A-10 90-8M0060785 DECEMBER 2011

Theory of Operation
Main Power Relay (MPR)

The main power relay is located on the starboard side of the engine behind the electrical cover. The main power relay is
controlled by the ECM. After the key is turned on, the main power relay is active for approximately five seconds. The ECM will
not continue to activate the main power relay unless one or more various sensors, or solenoid activation, signal the ECM to
initiate the main power relay. The main power relay supplies 12 volts to the fuel pumps inside the fuel supply module, ignition
coils, fuel injectors, and the alternator.
Intake Manifold
The intake manifold is located on the starboard side of the engine. It is mounted to the cylinder block and cylinder head. The
intake manifold is the mounting component for the throttle body, idle air control (IAC), manifold absolute pressure (MAP)
sensor, and manifold air temperature (MAT) sensor. The intake manifold is manufactured with a material that is extremely
strong, lightweight, and noncorrosive.
The intake manifold is designed with four runners to provide a smooth air flow to each of the combustion chambers. The
individual runners to the combustion chambers significantly increases the distribution of fuel atomization density within the
combustion chamber, producing a more complete combustion of the fuel air mix, which increases the fuel economy and
provides more horsepower.
Engine Control Module (ECM)

The ECM requires 8 volts minimum to operate. If the ECM should fail, the engine will stop running. The inputs to the ECM can
be monitored and tested using the CDS G3 Diagnostic Interface tool.

8M0046124
Harness
The ECM controls the following functions:

• Calculates the precise fuel and ignition timing requirements based on engine speed, throttle position, manifold absolute
pressure, manifold air temperature, and cylinder block coolant temperature.
• Directly controls the ground circuit to: fuel injectors, ignition coil, main power relay, fuel pumps, diagnostics, Engine
Guardian, and tachometer link (analog tachometer output or link gauge driver).
• Indirectly controls the positive circuit to: fuel injectors, ignition coils, and main power relay.
The ECM operates in three modes: stall, start, and run. The ECM also provides for a smooth throttle response between varying
throttle positions and engine loads. A warm‑up mode is integrated with the run mode and disengaged after the engine
accumulates a given amount of power or engine temperature.
With the ignition key switch "OFF," 12 volts are available from the battery at the fuses and at the alternator.
Stall mode ‑ With the ignition key switch in the "ON" position, the ECM is energized and supplies power to the main power
relay for five seconds. It also provides 5 volts power to the sensors. The ECM records barometric pressure from the MAP
sensor, intake air temperature from the MAT sensor, and coolant temperature from the cylinder block coolant temperature
sensor. The ECM will use this information to establish a warm‑up strategy that will control fuel delivery and engine speed during
warm‑up and idle.
Start mode ‑ When the vessel operator turns the key switch to the "START" position, a 12 volt signal is sent to the ECM to
begin the sequence of turning the engine over by energizing the start relay. The start relay transfers battery voltage to energize
the starter solenoid. While the engine rotates, a pulse will be generated at the crankshaft position sensor which provides the
ECM engine speed information and engages the main power relay. When the key switch is turned to the "START" position
while the engine is running in neutral, the engine will turn off. The ECM completes the ground circuit for the fuel pumps and the
main power relay.
Run mode ‑ At approximately 500 RPM, the ECM will transition to the run mode.
• The warm‑up strategy will continue to adjust engine speed with the fuel injector pulse width and engine spark advance until
the engine accumulates a given amount of power.
• The MAT sensor, TPS sensor, and MAP sensor are monitored to determine the proper spark timing and fuel needs
necessary to develop the amount of power asked for by the operator.
Throttle Body
The throttle body is located on the intake manifold. The throttle body is mechanically operated with a metal rod connected to a
cantilever throttle lever on the starboard side of the engine behind the intake manifold. The cantilever throttle lever position is
controlled at the helm through the remote control assembly or the tiller handle.
90-8M0060785 DECEMBER 2011 Page 3A-11

Theory of Operation
The idle air control, in conjunction with the throttle body, controls the volume of air entering the intake manifold at idle. A throttle
position sensor (TPS) is mounted on the throttle body and is directly linked to the throttle body valve shaft. As the demand for
engine power is needed, the throttle body valve opening is increased to allow more air to enter the intake manifold. The position
of the throttle valve is sent to the ECM through the TPS. The position of the throttle valve, along with the manifold absolute
pressure (MAP) sensor, the manifold air temperature (MAT) sensor, and the cylinder block coolant temperature sensor, assist
the ECM to determine the optimum fuel injection timing, duration, and the ignition timing.
a
a- Throttle body
c b- Metal rod
c- Throttle position sensor
b d- Idle air control (IAC)
d
47907

The IAC is located in the front of the intake manifold above the oil dipstick. The IAC is a modulated duty cycle electrically
operated spring‑loaded solenoid valve which controls the amount of air that bypasses the closed throttle shutter. Signals from
the ECM regulate the duty cycle of the IAC open time. The duty cycle ranges from 0% to 100% open. The IAC controls four
engine operation functions:
• Provides additional intake air (bypass) for engine start‑up
• Allows the increased idle RPM during engine warm‑up
• Controls idle speed according to varying engine loads and running conditions
• Functions as an electronic dashpot by providing additional bypass during rapid deceleration, preventing the engine from
stalling
47908
Fuel Supply Module (FSM)

The FSM contains the fuel lift pump, high‑pressure fuel pump, fuel pressure regulator, and the fuel cooler. The FSM is mounted
below the adapter plate at the rear of the engine. There is no needle and seat or float controlling the amount of fuel entering the
FSM. The filling of the FSM is provided by the positive displacement fuel lift pump. Modulation of the fuel lift pump is not
required.
The FSM is a volume displacement module. The volume of entrained air in the FSM, high‑pressure fuel line and the fuel rail,
must be purged to allow the fuel to reach the top fuel injector on the fuel rail. When the FSM is properly purged, it is almost
always completely filled. The fuel pumps are on parallel electrical circuit inside the FSM for power and ground. Power from the
main power relay activates the fuel lift pump and the high‑pressure fuel pump. Fuel pressure is controlled by the fuel pressure
regulator located inside the FSM.
Page 3A-12 90-8M0060785 DECEMBER 2011

Theory of Operation
Cooling of the fuel occurs with a bi‑level heat transfer. Inside the FSM are four metal tubes: two that are large diameter and two
that are smaller diameter. The smaller diameter tubes are inside the large diameter tubes. The large diameter tubes pass water
through them. The large diameter metal tubes cool the reservoir fuel in addition to cooling the fuel that passes through the
smaller diameter tubes from the high‑pressure pump and fuel pressure regulator.
c
b c a- Fuel pressure regulator manifold reference port
a b- High‑pressure fuel out port
c- Fuel cooler water in port
f
d- Fuel lift pump (from vessel)
c
e- Fuel cooler water out port
f- Fuel cooler fuel tube
d
e
47841
e
Fuel Lift Pump

The fuel lift pump located inside the FSM, pulls fuel from the fuel tank. The fuel lift pump is activated with 12 volts through the
main power relay when the key is turned to the "ON" position for approximately five seconds when there is no engine rotation.
The grounding of the fuel lift pump is completed in the ECM. The ECM does not have the logic to detect the fuel lift pump
operation. In the event of a fuel lift pump failure, no fault will be generated and the engine will not run.
The fuel lift pump has fuel passing through it constantly when the FSM is full of fuel. A fuel recirculating check valve inside the
FSM is conjoined with the fuel lift port passage. When fuel cannot be pulled into the FSM from the fuel tank (FSM is full), the
check valve opens and allows the cooled fuel inside the FSM to pass through the fuel lift pump, preventing the pump from
overheating. The FSM is a volume displacement module which replaces the fuel inside the FSM automatically without the
installation of a float switch or needle and seat.
47837
90-8M0060785 DECEMBER 2011 Page 3A-13

Theory of Operation
High‑Pressure Fuel Pump

When the ignition key is turned "ON," the high‑pressure fuel pump is active for approximately five seconds. After the first five
seconds, the high‑pressure fuel pump will not run until the ECM recognizes engine RPM. The ECM does not have the logic to
detect the high‑pressure fuel pump operation. In the event of a high‑pressure fuel pump failure, no fault will be generated and
the engine will not run. The high‑pressure fuel pump sends the fuel through a 20 micron fuel filter and into the bottom of the fuel
rail. There is an internal regulation of the high‑pressure pump of 689.5 kPa (100 psi). The fuel rail pressure is controlled by a
fuel pressure regulator. The fuel pressure dumped by the fuel pressure regulator passes through a fuel cooler. Passing the
excessive fuel through the fuel cooler prevents the high‑pressure fuel pump from overheating.
47839
Fuel Pressure Regulator

The fuel pressure regulator, located inside the fuel supply module, controls the amount of fuel pressure required for the engine
to run efficiently. The fuel pressure regulator changes the pressurization of the fuel depending on the demands of the engine.
Air pressure in the intake manifold changes to a higher or lower pressure during RPM changes. These manifold air pressure
changes are linked to the fuel pressure regulator. The changes which take place at the fuel pressure regulator are managed by
a hose that is connected to the intake manifold. The air pressure change that is positive or negative on the fuel pressure
regulator diaphragm, increases or decreases the amount of fuel that is returned back into the FSM. The fuel pressure dumped
by the fuel pressure regulator passes through a fuel cooler. Passing the excessive fuel through the fuel cooler prevents the
high‑pressure and low‑pressure fuel pumps from overheating.
47840
Page 3A-14 90-8M0060785 DECEMBER 2011

Theory of Operation
Fuel Injector
The fuel injector is an electrically operated spring‑loaded solenoid which delivers a metered amount of fuel into the intake
manifold runner, just ahead of the intake valve. The injectors are electrically charged when the key switch is turned to the "ON"
position. The ECM controls the injection by completing the ground circuit, lifting the solenoid, which allows high‑pressure fuel to
flow. The ECM then opens the ground circuit, allowing the spring to close the injector and stop the fuel flow. The fuel injector is
not serviceable. The fuel injector has an orifice plate which contains small holes. The orifice plate design allows for a better
atomization of the fuel with the air. The injectors spray the fuel directly at the intake valves. An injector filter is located on the
fuel inlet side of the injector. The filter is not replaceable but can be cleaned of debris.
a - O‑rings
b - Filter
a 48187
Guardian Protection System

The Guardian Protection System monitors critical engine functions and will reduce engine power accordingly in an attempt to
keep the engine running within safe operating parameters.
IMPORTANT: The Guardian Protection System cannot guarantee that powerhead damage will not occur when adverse
operating conditions are encountered. The Guardian Protection System is designed to 1) warn the boat operator that the
engine is operating under adverse conditions and 2) reduce power by limiting maximum RPM in an attempt to avoid or reduce
the possibility of engine damage. The boat operator is ultimately responsible for proper engine operation.
90-8M0060785 DECEMBER 2011 Page 3A-15

Theory of Operation
Fuel Flow Diagram

a- Fuel rail
b- High‑pressure fuel filter (20 microns)
c- Fuel supply module
d- High‑pressure fuel
e- Fuel pressure regulator
f- Fuel cooler
a g- High‑pressure fuel pump
h- Siphon tube
i- Fuel lift pump
j- Recirculation check valve
k- Fuel filter (20 microns)
l- Fuel from vessel
c
d e
f g h f i
j
47844
Page 3A-16 90-8M0060785 DECEMBER 2011

Troubleshooting and Diagnostics
Fuel System
Section 3B - Troubleshooting and Diagnostics
Table of Contents
3
Troubleshooting Without a CDS G3 Diagnostic Interface Idle Air Control (IAC) Testing......................................3B-5
Tool................................................................................ 3B-3 Fuel Pumps........................................................................3B-6
Fuel Supply Module Priming Procedure............................ 3B-3 Fuel Supply Module Fuel Pumps................................3B-6
Priming the FSM with a Purge Tool............................ 3B-3
Priming the FSM (Ran out of Fuel Condition) ............3B-4
Fuel Lift Pump ............................................................3B-7
High‑Pressure Fuel Pump.......................................... 3B-8
B
Anti‑Siphon Valves.............................................................3B-4 Fuel Injectors..................................................................... 3B-8
Referencing Fuel Pressure Readings................................ 3B-4 Fuel Injector and Harness Resistance Test................3B-9
Fuel Pressure Calculations, Engine Running.................... 3B-4 Fuel Injector and Harness Voltage Test..................... 3B-9
Idle Air Control (IAC)..........................................................3B-5
90-8M0060785 DECEMBER 2011 Page 3B-1


25 Liquid Neoprene Grounds and ring terminals 92- 25711 3
Special Tools
8M0046124
Harness
41993

V Hz
H z TEMP
mA
A
mV IG
OFF IP
TEMP
A mA COM V Hz
4516
Fuel Pressure Gauge Kit 91‑881833A03
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
Digital Pressure Meter 91‑892651A01
Connects to the fuel system/manifold and can be used in conjunction with

Computer Diagnostic System (CDS).
5786
Page 3B-2 90-8M0060785 DECEMBER 2011

Troubleshooting Without a CDS G3 Diagnostic Interface Tool

Troubleshooting without the CDS G3 Diagnostic Interface tool is limited to checking resistance on some of the sensors and
actuators.
Typical failures usually do not involve the engine control module (ECM). Most likely at fault are the connectors, setup, and
mechanical wear.
• The engine may not run or may not run above idle with the wrong spark plugs installed.
• Swap ignition coils to see if the problem follows the coil or stays with the particular cylinder.
NOTE: Some ECMs are capable of performing a cylinder misfire test to isolate problem cylinders. Once a suspect cylinder
is located, an output load test on the ignition coil or fuel injector can be performed using the CDS G3 Diagnostic Interface
tool.
• Any sensor or connection can be disconnected and reconnected while the engine is operating without damaging the ECM.
Disconnecting the crankshaft position sensor will stop the engine.
IMPORTANT: Any sensor that is disconnected while the engine is running will be recorded as a fault in the ECM Fault
History. Use the CDS G3 Diagnostic Interface tool to view and clear the fault history when troubleshooting/repair is
completed.
• If all cylinders exhibit similar symptoms, the problem is with a sensor or harness input to the ECM.
• If the problem is speed related or intermittent, it is probably connector or contact related. Inspect connectors for corrosion,
loose wires, or loose pins. Verify all the connectors are properly latched together and the engine harness is restrained with
cable ties or retainers as shown in the appropriate section of the Service Manual. If dielectric compound was used to
protect the wire connections, the dielectric compound must be removed.
• Inspect the harness for obvious damage: pinched wires, chafing.
• Secure grounds and all connections involving ring terminals. Apply Liquid Neoprene to all grounds and ring terminals.

25 Liquid Neoprene Grounds and ring terminals 92- 25711 3
• Check fuel pump connections and fuel pump pressure.
Fuel Supply Module Priming Procedure

The fuel supply module (FSM) is not vented to the ambient air. The air trapped in the FSM, fuel lines, and fuel rail, will be
slightly compressed during the initial ignition key "ON" with a dry or drained fuel system. Additional key "ON" events under
these conditions, will not compress the air further to finish the priming of the FSM. Excessive number of key "ON" events may
eventually damage the fuel pumps. The volume of air trapped in the FSM must be purged to prime the fuel system. This can be
achieved by connecting a tool to the fuel rail Schrader valve fitting to quickly purge the system into an approved container, or by
cranking the engine.
Priming the FSM with a Purge Tool

The use of a purge tool for priming the FSM is the preferred method, but is not always practical. The objective is to purge the
air entrained in the fuel system through a purge tool connected to the fuel rail Schrader valve test port. During the key "ON,"
opening the dump valve will allow the air to be purged from the FSM and fuel rail. This method should be used on vessels
where the fuel inlet system to the outboard is restrictive; anti‑siphon valve or holds a relatively large volume of fuel because of a
long fuel supply line or water separating fuel filter. If a primer bulb is installed, it can be used during the priming event to shorten
the amount of time required to start the engine.
4. Secure the fuel pressure gauge purge hose into an appropriate fuel container to collect excess fuel.
5. Open the fuel pressure gauge purge valve and turn the ignition key "ON." The fuel pumps will run for approximately five
seconds.
6. Turn the ignition key "OFF" and then back "ON." The fuel pumps will run for approximately five seconds. Continue this
ignition key cycle until the purged fuel is relatively clear of air bubbles.
NOTE: If the outboard fuel system does not prime within 15 key "ON" events, check for leaks in the fuel supply line to the
outboard. Repair as needed. If no leak is found, the fuel supply system to the outboard may be too restrictive. Correct the
condition and try again.
7. Remove the fuel pressure gauge.
8. Turn the ignition key "ON." When the fuel pumps stop running, start the engine. The engine may not start on the first
attempt. The engine will run rough at idle for up to two minutes while the residual air is purged from the fuel system.
90-8M0060785 DECEMBER 2011 Page 3B-3

Priming the FSM (Ran out of Fuel Condition)

The use of a purge tool for priming the FSM is the preferred method, but is not always practical. When the vessel fuel system is
void of fuel volume, it can be primed without the use of a purge tool. The objective is to purge the air entrained in the fuel
system through the fuel injectors during engine cranking to allow fuel to enter the fuel module. This method can be used on
vessels where the fuel inlet system to the outboard is less restrictive and holds a relatively small volume of fuel; a short fuel
supply line, no water separating fuel filter, or water separating fuel filter is already primed. If a primer bulb is installed, it can be
used during the priming event to shorten the amount of time required to start the engine.
3. Turn the ignition key "ON." The fuel pumps will run for approximately five seconds.
4. Turn the ignition key to the "START" position and release the key. The ECM controls the activation of the starter. The
starter may continue cranking for up to eight seconds.
NOTE: When priming a drained fuel system, residual fuel may cause the engine to flare and stall which shortens the
engine cranking event.
5. Continue with the ignition key "ON" and "START" sequence until the engine continues to run.
IMPORTANT: Allow the starter motor to cool for 20 to 30 seconds between full eight second crank events. Limit the
number of events to a maximum of 10 full eight second cranking events.
6. Once the engine starts, it may run rough at idle for up to two minutes while the residual air is purged from the fuel system.
7. If the fuel system will not prime within 10 full eight second cranking events, use the previous procedure Priming the FSM
with a Purge Tool to prime the fuel system.
Anti‑Siphon Valves
While anti‑siphon valves may be helpful from a safety standpoint, they clog with debris, they may be too small, or they may
have too heavy a spring. The pressure drop across these valves can, and often does, create operational problems and/or
powerhead damage by restricting fuel to the fuel lift pump and, subsequently, the high‑pressure fuel pump. Some symptoms of
restricted (lean) fuel flow, which could be caused by use of an anti‑siphon valve, are:
• Severe fuel rail pressure fluctuation
• Loss of fuel pump pressure
• High speed surging
• Outboard cuts out or hesitates upon acceleration
• Outboard runs rough
• Outboard quits and cannot be restarted
• Outboard will not start
• Vapor lock
Since any type of anti‑siphon device must be located between the outboard fuel inlet and fuel tank outlet, a simple method of
checking if such a device (or bad fuel) is a problem source, is to operate the outboard with a separate fuel supply which is
known to be good, such as a remote fuel tank.
If, after using a separate fuel supply, it is found that the anti‑siphon valve is the cause of the problem, there are two solutions to
the problem; either 1) replace the anti‑siphon valve with one that has a lighter spring tension, or 2) replace it with a
solenoid‑operated fuel shut off valve.
Referencing Fuel Pressure Readings

The fuel rail pressure is regulated by a fuel pressure regulator located inside the fuel supply module and is subject to
atmospheric differential pressure variance. The fuel pressure regulator pressure reference reading while the engine is static
(not running) is approximately 340–370 kPa (49.3–53.7 psi). The fuel pressure regulator is factory set to 350 ± 32 kPa
(50.76 ± 4.64 psi). A reference hose is connected between the intake manifold and the fuel pressure regulator. The intake
manifold pressure affects the amount of fuel pressure needed to unseat the fuel pressure regulator. The intake manifold
vacuum pressures pull on the fuel pressure regulator diaphragm, allowing the fuel pressure regulator to open at a lower
pressure than the factory set point. The amount of vacuum pressure inside the intake manifold is directly related to the engine
RPM and the position of the throttle.
Fuel Pressure Calculations, Engine Running

When calculating the fuel pressure at different points of engine RPM, a simple formula can be used to determine what the fuel
pressure should approximately be; (MAP – Barro) + regulator set point.
The following examples are with an ambient barometric pressure of 101 kPa (14.65 psi).
Page 3B-4 90-8M0060785 DECEMBER 2011

If the intake manifold absolute pressure is below the barometric pressure (vacuum), and the CDS G3 Diagnostic Interface tool
displays 32 kPa (4.64 psi) the formula appears as:
• kPa: 32 – 101 = –69 + 350 = 281. The calculated fuel pressure reading is 281 kPa.
• PSI: 4.64 – 14.65 = –10.1 + 50.76 = 40.66. The calculated fuel pressure reading is 40.66 psi.
If the intake manifold absolute pressure is above the barometric pressure and the CDS G3 Diagnostic Interface tool displays
191 kPa (27.70 psi) the formula appears as:
• kPa: 191 – 101 = 90 + 350 = 440. The calculated fuel pressure reading is 440 kPa.
• PSI: 27.70 – 14.65 = 13.05 + 50.76 = 63.81. The calculated fuel pressure reading is 63.81 psi.

The IAC is located on the intake manifold. The IAC is a modulated duty cycle electrically operated spring‑loaded solenoid valve
which controls the amount of air that bypasses the closed throttle shutter. Signals from the ECM regulate the duty cycle of the
IAC open time. The duty cycle ranges from 0% to 100% open.
One side of the IAC valve is exposed to the ambient air pressures under the cowl. The other side of the IAC valve is exposed to
the intake manifold vacuum pressures. When the IAC is activated, the armature lifts, opening the control orifice which is
normally spring‑loaded closed. The IAC valve has a rubber stopper on the end of it.
47908
Idle Air Control (IAC) Testing

The IAC can be tested with the CDS G3 Diagnostic Interface tool.

8M0046124
Harness
1. Disconnect the engine harness from the IAC.

2. Disconnect the engine harness ECM connector at the ECM.
3. Use the DMT 2004 digital multimeter to perform an ohm check on the engine harness between the IAC connection and the
ECM connection.

4. Set the meter to read ohms, auto scale.
5. Connect the red meter lead to the ECM connector, pin 3.
6. Connect the black meter lead to the IAC harness connector, pin 1.
7. If the results of the test is not within specifications, check for corrosion or an open connection. Repair as needed.
8. Connect the red meter lead to the ECM connector, pin 57 or 58. These two wires are spliced in the harness.
9. Connect the black meter lead to the IAC harness connector, pin 2.
90-8M0060785 DECEMBER 2011 Page 3B-5

10. If the results of the test is not within specifications, check for corrosion or an open connection. Repair as needed.
d
b
c
34 51
WHT/LT BLU
18
RED/BLU
1
67
a B A
68
57
58
69
70
17 33 50 66 48925
a- ECM connector
b- IAC harness connector
c- Main power relay
d- 20 amp fuse
Meter Test Leads

Red Black
ECM connector, pin 3 IAC harness connector, pin 1 (white/Lt blue) Auto Less than 1
ECM connector, pin 57 or 58 IAC harness connector, pin 2 (red/blue) Auto Less than 1
11. Connect the engine harness to the IAC.
12. Connect the engine harness ECM connector to the ECM.
Fuel Pumps
Fuel Supply Module Fuel Pumps
The fuel lift pump and high‑pressure pump is activated with 12 volts through the main power relay when the key is turned to the
"ON" position. The fuel pump circuit, in conjunction with the idle air control, fuel injectors, and start relay, are protected with a
20 amp fuse. The grounding of the fuel pump circuit is completed inside the engine control module. Modulation of the fuel lift
pump is not required because the fuel delivery system is one way and deadheads at the top of the fuel rail.
Page 3B-6 90-8M0060785 DECEMBER 2011

The fuel lift pump and high‑pressure pump are on a parallel circuit inside the fuel supply module and cannot be electrically
tested separately when installed as part of the fuel supply module assembly. The fuel pumps will run for approximately five
seconds when ignition key is turned "ON" and no engine rotation is sensed by the engine control module. While the fuel pumps
are active, a vacuum test on the fuel lift pump, and a pressure reading on the high‑pressure pump, should be performed when
troubleshooting the fuel pumps. The fuel pumps circuit can be activated by the CDS G3 Diagnostic Interface tool.
d
b c
1 18 34 51
RED/WHT
RED
RED/YEL
RED/ORN
RED
RED/WHT
RED/BLU
RED/PPL
67
a
YEL/PPL
RED/WHT
RED/PPL
RED
68
RED/BLU
RED/BLK
69
70
17 33 50 66
48881
a- ECM connector
b- High‑pressure fuel pump
c- Fuel lift pump
d- 20 amp fuse
e- Main power relay
Fuel Lift Pump

The fuel lift pump and high‑pressure pump are on a parallel circuit inside the fuel supply module. The fuel lift pump cannot be
electrically tested separately from the high‑pressure pump when installed as part of the fuel supply module assembly. The fuel
lift pump can be tested for operation electrically with the CDS G3 Diagnostic Interface tool.

8M0046124
Harness
The fuel lift pump is activated with 12 volts through the main power relay when the key is turned to the "ON" position. The fuel
pump circuit, in conjunction with the idle air control, fuel injectors, and start relay, are protected with a 20 amp fuse. The
grounding of the fuel pump circuit is completed inside the engine control module. Modulation of the fuel lift pump is not required
because the fuel delivery system is one way and deadheads at the top of the fuel rail.
There is no logic in the engine control module to know if the fuel lift pump is functioning or not. No fault will be set if the fuel lift
pump fails.
Testing Fuel Lift Pump Vacuum

1. Separate the engine fuel line and the boat fuel line.
2. Install a T‑fitting on the boat fuel line.
3. Install a clear fuel line on the opposite side of the T‑fitting. Connect the clear fuel line to the engine fuel line.
4. Install a fuel vacuum gauge (obtain locally) on the T‑fitting.
5. Clamp all fuel line connections securely to prevent vacuum leaks.
90-8M0060785 DECEMBER 2011 Page 3B-7

6. Start the engine and observe the clear fuel line for air bubbles. If the engine does not start, use the CDS G3 Diagnostic
Interface tool.
7. The vacuum gauge reading should be within the listed specification when the pump is active.
a- Engine fuel line

b- Clear fuel line
c- T‑fitting
d- Boat fuel line
a d
b c
4439
Fuel Lift Pump Vacuum

Maximum 10.16 kPa (3.00 in. Hg)

The high‑pressure fuel pump and fuel lift pump are on a parallel circuit inside the fuel supply module. The high‑pressure fuel
pump cannot be electrically tested separately from the fuel lift pump when installed as part of the fuel supply module assembly.
The high‑pressure fuel pump can be tested for operation electrically with the CDS G3 Diagnostic Interface tool.

8M0046124
Harness
The high‑pressure fuel pump is activated with 12 volts through the main power relay when the key is turned to the "ON"
position. The fuel pump circuit, in conjunction with the idle air control, fuel injectors, and start relay, are protected with a 20 amp
fuse. The grounding of the fuel pump circuit is completed inside the engine control module. The fuel delivery system is one way
and deadheads at the top of the fuel rail.
There is no logic in the engine control module to know if the high‑pressure fuel pump is functioning or not. No fault will be set if
the high‑pressure fuel pump fails.
Fuel Pressure Gauge Kit 91‑881833A03

Dual Fuel/Air Pressure Gauge Kit 91‑881834A 1
Digital Pressure Meter 91‑892651A01
2. Perform the fuel pump load test with the CDS.
3. The fuel pressure gauge should be within specifications.

Fuel pressure, engine not running 340–370 kPa (49.3–53.7 psi)
Fuel pressure, engine running Pressure dependent on manifold vacuum pressure
4. If there is little or no pressure reading on the gauge, ensure the fuel supply module has enough fuel to supply the
high‑pressure fuel pump. It may be necessary to perform a fuel supply module priming to verify the system is purged of
entrained air.
Fuel Injectors
The fuel injector is an electrically operated spring‑loaded solenoid, which delivers a metered amount of fuel into the intake
manifold runner, just ahead of the intake valve. The injectors are electrically charged through the main power relay when the
ignition key is turned to the "ON" position. The engine control module controls the injection by completing the ground circuit,
lifting the solenoid, which allows high‑pressure fuel to flow. The engine control module then opens the ground circuit allowing
the spring to close the injector and stop the fuel flow. The fuel injector is not serviceable. An injector filter is located on the fuel
inlet side of the injector. The filter is not replaceable, but can be cleaned of debris. The fuel injectors can be tested with an
ohmmeter or the CDS G3 Diagnostic Interface tool.

8M0046124
Harness
Page 3B-8 90-8M0060785 DECEMBER 2011

Fuel Injector and Harness Resistance Test

c d e
b f g
RED/BLU
RED/BLU
RED/BLU
RED/PNK
ORN/PNK
YEL/PNK
BRN/PNK
RED/BLU
RED/BLU
1 18 34 51
67 a
68
57
69
58
70 48865
17 33 50 66
a- ECM connector
b- Fuel injector #1
c- Fuel injector #2
d- Fuel injector #3
e- Fuel injector #4
f- Main power relay
g- 20 amp fuse
1. Verify the fuse is good.

2. Disconnect the engine harness ECM connector at the ECM.
3. Use the DMT 2004 digital multimeter to perform an ohm check on each of the injector circuits.
4. If the resistance is out of specification, disconnect the engine harness connector from the fuel injector and test the fuel
injector for the resistance specification.
5. If the injector is in specification, connect the engine harness connector. Shake or move the harness and connector. If the
meter readings change during the tests, inspect for a broken, loose, or corroded wire. Repair the problem wire and test the
circuit.
Meter Test Leads

Red Black
Pin 49 (fuel injector #1) (brown/pink) Auto 12 ± 0.5
Pin 50 (fuel injector #2) (red/pink) Auto 12 ± 0.5
Pin 57 or 58 (red/blue)
Pin 65 (fuel injector #3) (orange/pink) Auto 12 ± 0.5
Pin 48 (fuel injector #4) (yellow/pink) Auto 12 ± 0.5
Fuel Injector and Harness Voltage Test

1. Perform a visual inspection of the pins at the fuel injector and the wires coming to the engine harness connector. Look for
broken, bent, and corroded pins at the fuel injector; and loose, broken, or corroded wires at the engine harness connector.
90-8M0060785 DECEMBER 2011 Page 3B-9

NOTE: Shake or move the harness and connector when performing the following tests. If the meter readings change
during the tests, inspect for a broken, loose, or corroded wire. Repair the problem wire and retest the circuit.
2. Connect the meter between the red/blue pin at the fuel injector connector and a common engine ground. Ensure the meter
is set to read voltage, auto scale.
3. Turn the ignition key switch to the "ON" position.
NOTE: With the ignition key switch in the "ON" position and the engine off, battery voltage is only available to the red/blue
wire for five seconds when no crankshaft position sensor signal is received by the engine control module.
a. If battery voltage is not present, check to ensure the main power relay is functioning.
b. If battery voltage is not present and the main power relay is functioning properly, check to ensure the 20 amp fuse is
not blown.
NOTE: The main power relay must be on for battery voltage to be present at the red/blue wire. If battery voltage is not
present, the main power relay may be defective or the 20 amp fuse is blown.
c. If battery voltage is not present with the main power relay functioning properly, and the fuel injector fuse is not blown,
there is an open circuit between the main power relay red/blue wire and the splice in the engine harness connector.
NOTE: 12 volt power supply for the fuel injectors are spliced together at several different locations in the engine
harness. If the red/blue wire at the fuel supply module fuel pump connector and all of the fuel injector red/blue wires
have no battery voltage, an open circuit at the engine wire harness splice point is the most likely failure.
4. Check for continuity between the red/blue wire on each of the fuel injector engine harness connectors and the red/white
wire at the main power relay. This test includes the fuel injector fuse. Ensure the fuel injector fuse is not blown.
Page 3B-10 90-8M0060785 DECEMBER 2011

Service Procedures
Fuel System
Section 3C - Service Procedures
Table of Contents
3
Fuel System Specifications................................................3C-2 Fuel Rail Assembly and Installation............................3C-6
Throttle Body..................................................................... 3C-2 Fuel Supply Module (FSM)................................................ 3C-8
Throttle Body Removal............................................... 3C-2 FSM Removal.............................................................3C-8
Throttle Body Installation............................................ 3C-3
Fuel Rail.............................................................................3C-5
FSM Disassembly.....................................................3C-10
FSM Assembly......................................................... 3C-13
C
Fuel Rail Removal and Disassembly..........................3C-5 FSM Installation........................................................3C-20
90-8M0060785 DECEMBER 2011 Page 3C-1

Service Procedures

Automotive unleaded with a minimum pump posted octane rating of 87 (90
Type of fuel
RON)
Approximate fuel pressure at idle 280–310 kPa (40.6–45.0 psi)
Approximate fuel pressure engine not running 340–370 kPa (49.3–53.7 psi)
Fuel filtration
Fuel inlet 20 microns
High pressure 20 microns

O-rings
Seal grommet
95 2-4-C with PTFE 92-802859A 1
Fuel pressure regulator O-rings
O-rings and seal grommets
Special Tools
Clamp Tool 91‑803146T
Used to clamp high‑pressure (Oetiker®) hose clamps. Part of Clamp Tool Kit
39648 (91‑803146A4).
Throttle Body
Throttle Body Removal
1. Remove the flywheel cover.
2. Remove the vent hose assembly from the throttle body.
4. Disconnect the engine harness connector from the throttle position sensor.
a a - Vent hose assembly

b - Throttle link
c - Throttle position sensor engine harness
c connector
48115
Page 3C-2 90-8M0060785 DECEMBER 2011

Service Procedures
5. Remove four screws securing the throttle body to the intake manifold. Remove the throttle body from the manifold.
48116
6. Remove the two screws securing the throttle position indicator to the throttle body. Remove the throttle position indicator.
a - Throttle position indicator

b - Screws (2)
a
b 48117
Throttle Body Installation

1. Install the throttle position indicator onto the throttle body throttle shaft.
2. Rotate the throttle position indicator clockwise to align the screw holes.
48118
90-8M0060785 DECEMBER 2011 Page 3C-3

Service Procedures
3. Install the screws and tighten to the specified torque.
a - Throttle position indicator

b - Screws (2)
a
b 48117

Throttle position indicator screws (2) 2.3 20.3
4. Replace the throttle body seal on the intake manifold.
48119
5. Install the throttle body and secure with four M6 x 20 screws. Tighten the screws to the specified torque.
48116

Screws (M6 x 20) (4) 8 70.8
6. Connect the engine harness connector to the throttle position sensor.

Page 3C-4 90-8M0060785 DECEMBER 2011

Service Procedures
8. Install the vent hose assembly onto the throttle body.
a a - Vent hose assembly

b - Throttle link
c - Throttle position sensor engine harness
c connector
48115
Fuel Rail
Fuel Rail Removal and Disassembly
Fuel Rail Removal
! WARNING
! CAUTION
Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the
engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and
skin from pressurized fuel and vapors.

2. Connect a fuel pressure gauge to the fuel rail test port and release the fuel pressure into an appropriate container.
3. Remove the metal hose clamp and remove the high‑pressure fuel hose from the fuel rail. Capture the fuel that will drain
from the fuel rail and high‑pressure fuel hose into an appropriate container.
a a - Fuel rail
b - Metal hose clamp
48183
4. Disconnect the engine harness connectors from the fuel injectors.
5. Remove the screws securing the fuel rail to the intake manifold.
90-8M0060785 DECEMBER 2011 Page 3C-5

Service Procedures
6. Pull the fuel rail assembly off of the intake manifold.
a - Engine harness connectors

b - Screws securing the fuel rail
c - Fuel rail test port
a b
48185
Fuel Rail Disassembly

1. Push the fuel injector retainer off of the fuel injector and fuel rail.
2. Pull the fuel injector off the fuel rail.
a - Fuel injector retainer
48186
Fuel Rail Assembly and Installation

Fuel Rail Assembly
IMPORTANT: The fuel injector filter is not serviceable, but can be cleaned with a mild solvent and compressed air.
1. Before installing the fuel injectors, flush the fuel rail with a mild solvent. Use compressed air to remove any possible debris
from inside the fuel rail.
Page 3C-6 90-8M0060785 DECEMBER 2011

Service Procedures
2. Replace the fuel injector O‑rings.
a - O‑rings
b - Filter
a 48187
3. Push the filter end of the fuel injector into the fuel rail. Verify the fuel injector retainer groove is above the fuel rail injector
port.
48188
4. Align the fuel injector retainer with the fuel rail and the fuel injector retainer groove.
5. Push the fuel injector retainer onto the fuel rail and fuel injector.
a - Fuel injector retainer
48191
Fuel Rail Installation

1. Push the fuel rail assembly onto the intake manifold and secure with four M6 x 20 screws. Tighten the screws to the
specified torque.
90-8M0060785 DECEMBER 2011 Page 3C-7

Service Procedures
2. Connect the engine harness connectors onto the fuel injectors.
a - Engine harness connectors

b - Screws securing the fuel rail
a b
48192

Screws (M6 x 20) 8 70.8
3. Install a 15.7 mm metal hose clamp onto the high‑pressure fuel hose.
4. Install the high‑pressure fuel hose onto the fuel rail.
5. Secure the hose with the metal hose clamp using the hose clamp tool.
a a - Fuel rail
b - Metal hose clamp
48183

Fuel Supply Module (FSM)

FSM Removal
1. Release the fuel pressure on the fuel rail. Refer to Fuel Rail Removal.
! CAUTION
Page 3C-8 90-8M0060785 DECEMBER 2011

Service Procedures
IMPORTANT: The FSM does not have a drain port incorporated into the upper or lower housing. If the FSM requires
disassembly, the extraction of fuel in the FSM can be accomplished with the following method.
Disconnect the fuel supply hose on the FSM. Attach a fuel pressure gauge to the fuel rail test port. Drain the fuel with the
pressure gauge into an appropriate container by turning the key switch "ON" several times while holding the purge valve
open, or use the CDS G3 Diagnostic Interface tool to energize the fuel pumps.
2. Disconnect all batteries from the engine.
3. Remove the remote control harness, fuel line, throttle, and shift cables.
4. Remove the lower cowls. Refer to Section 4A ‑ Lower Cowl.
5. Remove the screw securing the muffler to the adapter plate.
6. Cut the cable tie securing the hose to the muffler. Remove the muffler from the hose.
b a - Screw
b - Cable tie
a
48054
7. Cut the cable tie securing the fuel pump harness connector to the MAT sensor harness.
8. Disconnect the fuel pump harness connector from the engine harness.
9. Remove the 15.7 mm metal hose clamp securing the high‑pressure fuel line to the fuel rail. Remove the high‑pressure fuel
line from the fuel rail.
10. Remove the manifold pressure reference line from the FSM.
11. Cut the cable tie securing the FSM cooling water supply hose and remove the hose.
a - Metal hose clamp securing the high‑pressure fuel

a b line
b - MAT sensor harness
c - Cable tie securing the fuel pump harness connector
d - Manifold pressure reference line
e - Cable tie securing hose (hidden)
c
d
49244
12. Remove the screw and washer securing the FSM to the driveshaft housing.
13. Cut the cable tie securing the water hose and remove the hose.
14. Push the lock in and remove the fuel hose from the FSM.
NOTE: Fuel will drain from this hose when it is disconnected. Use an appropriate container to capture the fuel.
90-8M0060785 DECEMBER 2011 Page 3C-9

Service Procedures
15. Pull the FSM out of the grommet to remove.
a- Grommet
a b- Screw and washer
c- Cable tie
d- Fuel hose
c 49248
FSM Disassembly
NOTE: The FSM cannot be completely drained of fuel prior to disassembly. Use appropriate containers to capture fuel during
the disassembly process. Wipe up fuel spills immediately and dispose of in an appropriate container.
1. Place the FSM in an appropriate container to capture any fuel that will spill.
2. Remove the metal hose clamp securing the high‑pressure hose to the FSM upper housing and remove the hose.
49257
3. Remove the four screws securing the upper housing to the lower housing.
a - Screws (4)
49136
4. Grasp the lower housing and the upper housing and push the upper housing slightly to partially separate the upper housing
from the lower housing.
Page 3C-10 90-8M0060785 DECEMBER 2011

Service Procedures
5. Insert two pry tools between the upper and lower housing and carefully separate the housing.
NOTE: Use caution when separating the housing. The lower housing may be completely filled with fuel.
49141
6. Carefully lift the upper housing to access the power wire connections.
7. Disconnect the upper housing power wires from the fuel pump connectors and remove the O‑ring.
a - Power wires
b - O‑ring
a
49144
NOTE: Some of the internal components may be adhering to the upper housing when separated. Remove the fuel pumps
with an appropriate tool. Use caution not to twist the fuel pumps when removing them. Use a vice grip tool to clamp onto
the manifold webbing and pull the manifold out of the upper housing.
a - Manifold webbing
49318
90-8M0060785 DECEMBER 2011 Page 3C-11

Service Procedures
8. Remove the manifold from the tubes and fuel pumps.
a- Manifold
b- Lift fuel pump
c- Tubes (4)
a d- High‑pressure fuel pump
b
d
c 49147
9. Remove the tubes and fuel pumps from the lower housing.
IMPORTANT: If the fuel pumps are difficult to remove, use an appropriate tool to extract them. Use caution not to twist the
fuel pumps when removing.
a - Fuel tube (2)

b - Water tube (2)
a
b
49150
10. Remove the seal grommets from the manifold.
a - High‑pressure fuel pump seal grommet

b - Fuel lift pump seal grommet
a
b
49155
Page 3C-12 90-8M0060785 DECEMBER 2011

Service Procedures
11. Remove three O‑rings and a spacer from the manifold.
a - O‑rings
b b - Spacer on fuel pressure regulator
a
49156
12. Carefully spread the retainers and remove the fuel pressure regulator.
IMPORTANT: Use extreme care not to spread the retainers excessively. Spreading the retainers excessively will cause the
retainer to break off the manifold.
13. Remove the O‑ring and spacer from the fuel pressure regulator.
a - O‑ring
b - Spacer
a
b
49158
14. Inspect the inside of the upper and lower housings for seal grommets and remove them.
49162
15. Remove the fuel pump wire harness seal grommet from the upper housing by pushing on the seal grommet from the
outside of the upper housing with a blunt tool.
FSM Assembly
1. Install the O‑rings onto the water tubes and fuel tubes.
90-8M0060785 DECEMBER 2011 Page 3C-13

Service Procedures
2. Lubricate the O‑rings on the tubes with 2‑4‑C with PTFE.
a
a - O‑rings
b - Water tube
c - Fuel tube
c
49167
3. Install the fuel tubes into the lower housing.
49168

95 2-4-C with PTFE O-rings 92-802859A 1
4. Install the water tubes.
b a - Water tube
a b - Fuel tube
49199
Page 3C-14 90-8M0060785 DECEMBER 2011

Service Procedures
5. Install the seal grommet halfway onto the high‑pressure fuel pump outlet.
49206
6. Lubricate the seal grommet with 2‑4‑C with PTFE and install the high‑pressure fuel pump into the lower housing so the
wires are between the webbing and the water tube.
49213
49211
Wires between webbing Close up view without tube installed

95 2-4-C with PTFE Seal grommet 92-802859A 1
7. Install the seal grommet onto the fuel lift pump and lubricate with 2‑4‑C with PTFE.
49214

8. Install the fuel lift pump into the lower housing so the outlet port of the pump faces towards the center of the FSM.
9. Install the seal grommet halfway onto the outlet port of the fuel lift pump.
10. Install the seal grommet onto the high‑pressure fuel pump.
90-8M0060785 DECEMBER 2011 Page 3C-15

Service Procedures
11. Lubricate both seal grommets with 2‑4‑C with PTFE.
a - Fuel lift pump seal grommet

a b - High‑pressure fuel pump seal grommet
49217

12. Install two O‑rings onto the manifold.
13. Verify the hole in the manifold is open and that no debris partially blocks the hole.
IMPORTANT: Use only appropriate solvents and compressed air to remove debris which may be blocking the hole. Do not
use wire or any ridged material that may damage the hole.
a a - Hole in manifold
b - O‑rings
49165
14. Carefully install the manifold while aligning the fuel pumps and tubes. Verify the manifold is seated on the fuel pumps.
Ensure the fuel pump wires are not binding between the water tube and the fuel pump.
a - Manifold seated on fuel pump

b - Wires are not binding
a
b 49223
15. Verify the spacer is installed onto the fuel pressure regulator.
Page 3C-16 90-8M0060785 DECEMBER 2011

Service Procedures
16. Verify the fuel pressure regulator filter is clear of debris.
NOTE: The fuel pressure regulator filter is not a serviceable part, but can be cleared of debris with a mild solvent and
low‑pressure compressed air.
17. Install the O‑rings onto the fuel pressure regulator and lubricate them with 2‑4‑C with PTFE.
b a - Spacer
c b - Filter
c - O‑rings
a
49164

95 2-4-C with PTFE Fuel pressure regulator O-rings 92-802859A 1
18. Install the fuel pressure regulator onto the manifold.
19. Install the spacer and O‑ring onto the fuel pressure regulator.
a a - O‑ring
b b - Spacer
49225
20. Install the seal grommet halfway onto the manifold.

21. Insert the red wire harness connector onto the fuel lift pump positive terminal.
a - Red wire
b - Seal grommet
b
49226
22. Install the O‑ring onto the upper housing.

23. Install new O‑rings onto the fuel pump wire harness seal grommet. Verify the blue O‑ring is installed on the upper groove of
the seal grommet. Lubricate the O‑rings with 2‑4‑C with PTFE.
90-8M0060785 DECEMBER 2011 Page 3C-17

Service Procedures
24. Pull on the wire harness to seat the seal grommet into the upper housing. A gentle push on the seal grommet on the inside
of the housing with a blunt tool will ensure it is properly seated.
a a - Upper housing O‑ring

b - Blue O‑ring
b c - Second O‑ring on seal grommet
c
49231

95 2-4-C with PTFE O-rings 92-802859A 1
25. Connect the red wire from the upper housing to the positive terminal on the fuel lift pump.
26. Connect the black wire from the upper housing to the negative terminal on the fuel lift pump.
27. Connect the high‑pressure fuel pump black wire to the terminal on the fuel lift pump.
28. Lubricate all the visible O‑rings and seal grommets with 2‑4‑C with PTFE.
a - Black wires
b - Red wires
a b
49234

95 2-4-C with PTFE O-rings and seal grommets 92-802859A 1
Page 3C-18 90-8M0060785 DECEMBER 2011

Service Procedures
29. Verify the wires will not become pinched and install the upper housing.
49237
30. Carefully push the upper housing into the lower housing until there is no gap between the upper and lower housing.
IMPORTANT: If the gap between the upper and lower housing cannot be closed, the wires may be pinched or a seal
grommet is not properly aligned.
31. Install the screws and tighten the screws to the specified torque.
a - No gap
b - Screw (4)
a
49240

Screw 10 88.5
32. Install a 15.7 mm metal hose clamp onto the high‑pressure hose and install the hose onto the FSM upper housing. Use the
hose clamp tool to secure the hose to the FSM.
49257
90-8M0060785 DECEMBER 2011 Page 3C-19

Service Procedures
FSM Installation
1. Install the FSM into the grommet on the adapter plate.
2. Secure the FSM to the driveshaft housing with the M6 x 25 flange head screw and washer. Tighten the screw to the
specified torque.
3. Push the fuel hose onto the FSM far enough to lock it in place.
4. Install the exhaust cooling hose to the fitting and secure with a cable tie.
a- Grommet
a b- Screw and washer
c- Cable tie
d- Fuel hose
c 49248

Screw (M6 x 25) 8 70.8
5. Install the FSM cooling water supply hose onto the FSM and secure with a cable tie.
6. Install a 15.7 mm metal hose clamp onto the high‑pressure fuel line. Install the high‑pressure fuel line to the fuel rail. Use
the clamp tool to secure the hose to the rail.
7. Connect the fuel pump harness connector to the engine harness connector and secure the fuel pump harness connector to
the MAT sensor harness.
8. Connect the manifold pressure reference line to the FSM.

a b line
c - Cable tie securing the fuel pump harness connector
e - Cable tie securing hose (hidden)
c
d
49244

9. Install the muffler and secure it to the adapter plate with a M6 x 12 screw. Tighten the screw to the specified torque.
Page 3C-20 90-8M0060785 DECEMBER 2011

Service Procedures
10. Secure the hose to the muffler with a cable tie.
b a - Screw
b - Cable tie
a
48054

Screw (M6 x 12) 6 53.1
11. Connect the battery cables.
12. Install the lower cowls. Refer to Section 4A ‑ Lower Cowl.
13. Purge the fuel supply module. Refer to Section 3B ‑ Fuel Supply Module Priming Procedure.
90-8M0060785 DECEMBER 2011 Page 3C-21

Service Procedures
Notes:
Page 3C-22 90-8M0060785 DECEMBER 2011

Emissions
Fuel System
Section 3D - Emissions
Table of Contents
3
Exhaust Emission Standards.............................................3D-2 Manufacturer's Responsibility.....................................3D-3
What Are Emissions?................................................. 3D-2 Dealer Responsibility..................................................3D-3
Hydrocarbons – HC.................................................... 3D-2 Owner Responsibility..................................................3D-3
Carbon Monoxide – CO.............................................. 3D-2
Oxides of Nitrogen – NOx...........................................3D-2
EPA Emission Regulations.........................................3D-4
Manufacturer's Certification Label..................................... 3D-4
D
Controlling Emissions................................................. 3D-2 Service Replacement EPA Decal...................................... 3D-4
Stoichiometric (14.7:1) Air/Fuel Ratio.........................3D-2 Removal..................................................................... 3D-4
Outboard Hydrocarbon Emissions Reduction....................3D-3 Date Code Identification............................................. 3D-5
Emissions Information....................................................... 3D-3 Installation.................................................................. 3D-5
Models Affected..........................................................3D-3
90-8M0060785 DECEMBER 2011 Page 3D-1

Emissions
Exhaust Emission Standards

Through the Environmental Protection Agency (EPA), the federal government has established exhaust emissions standards for
all new marine engines sold in the U.S.
What Are Emissions?

Emissions are what comes out of the exhaust system in the exhaust gas when the engine is running. They are formed as a
result of the process of combustion or incomplete combustion. To understand exhaust gas emissions, remember that both air
and fuel are made of several elements. Air contains oxygen and nitrogen among other elements; gasoline contains mainly
hydrogen and carbon. These four elements combine chemically during combustion. If combustion were complete, the mixture
of air and gasoline would result in these emissions: water, carbon dioxide and nitrogen, which are not harmful to the
environment. But combustion is not usually complete. Also, potentially harmful gases can be formed during and after
combustion.
All marine engines must reduce the emission of certain pollutants, or potentially harmful gases, in the exhaust to conform with
levels legislated by the EPA. Emissions standards become more stringent each year. Standards are set primarily with regard to
three emissions: hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx).
Hydrocarbons – HC
Gasoline is a hydrocarbon fuel. The two elements of hydrogen and carbon are burned during combustion in combination with
oxygen. But they are not totally consumed. Some pass through the combustion chamber and exit the exhaust system as
unburned gases known as hydrocarbons.
Carbon Monoxide – CO
Carbon is one of the elements that make up the fuel burned in the engine along with oxygen during the combustion process. If
the carbon in the gasoline could combine with enough oxygen (one carbon atom with two oxygen atoms), it would come out of
the engine in the form of carbon dioxide (CO2). CO2 is a harmless gas. But carbon often combines with insufficient oxygen
(one carbon atom with one oxygen atom). This forms carbon monoxide, CO. Carbon monoxide is the product of incomplete
combustion and is a dangerous, potentially lethal gas.
Oxides of Nitrogen – NOx

NOx is a slightly different by‑product of combustion. Nitrogen is one of the elements that makes up the air going into the
engine. Under extremely high temperatures it combines with oxygen to form oxides of nitrogen (NOx). This happens in the
engine's combustion chambers when temperatures are too high. NOx itself is not harmful, but when exposed to sunlight it
combines with unburned hydrocarbons to create the visible air pollutant known as smog. Smog is a serious problem in
California as well as many other heavily populated areas of the United States.
Controlling Emissions
There are two principle methods of reducing emissions from a two‑stroke‑cycle marine engine. The first method is to control the
air/fuel ratio that goes into the combustion chamber. The second is to control the time when this air/fuel mixture enters the
combustion chamber. Timing is important, to prevent any unburned mixture from escaping out of the exhaust port.
Stoichiometric (14.7:1) Air/Fuel Ratio

In the search to control pollutants and reduce exhaust emissions, engineers have discovered that they can be reduced
effectively if a gasoline engine operates at an air/fuel ratio of 14.7:1. The technical term for this ideal ratio is stoichiometric. An
air/fuel ratio of 14.7:1 provides the best control of all three elements in the exhaust under almost all conditions. The HC and CO
content of the exhaust gas is influenced significantly by the air/fuel ratio. At an air/fuel ratio leaner than 14.7:1, HC and CO
levels are low, but with a ratio richer than 14.7:1 they rise rapidly. It would seem that controlling HC and CO by themselves
might not be such a difficult task; the air/fuel ratio only needs to be kept leaner than 14.7:1. However, there is also NOx to
consider.
As the air/fuel ratio becomes leaner, combustion temperatures increase. Higher combustion temperatures raise the NOx
content of the exhaust. But, enrichening the air/fuel ratio to decrease combustion temperatures and reduce NOx also increases
HC and CO, as well as lowering fuel economy. So the solution to controlling NOx ‑ as well as HC and CO ‑ is to keep the air/
fuel ratio as close to 14.7:1 as possible.
Page 3D-2 90-8M0060785 DECEMBER 2011

Emissions
Outboard Hydrocarbon Emissions Reduction

120
100
80
60
40
20
0 22523
96 97 98 99 2000 01 02 03 04 05 06 07 08
8-1/3% change per year over 9 model years
Emissions Information
Models Affected
Models Covered Serial Number or Year
Mercury/Mariner/Force/Sport Jet 2.5–250 HP 1998 and Newer
Manufacturer's Responsibility
Beginning with 1998 model year engines, manufacturers of all marine propulsion engines must determine the exhaust emission
levels for each engine horsepower family and certify these engines with the United States Environmental Protection Agency
(EPA). A certification decal/emissions control information label, showing emission levels and engine specifications directly
related to emissions, must be placed on each engine at the time of manufacture.
Dealer Responsibility
When performing service on all 1998 and newer outboards that carry a certification, attention must be given to any adjustments
that are made that affect emission levels.
Adjustments must be kept within published factory specifications.
Replacement or repair of any emission related component must be executed in a manner that maintains emission levels within
the prescribed certification standards.
Dealers are not to modify the engine in any manner that would alter the horsepower or allow emission levels to exceed their
predetermined factory specifications.
Exceptions include manufacturer's prescribed changes, such as that for altitude adjustments. Also included would be factory
authorized:
• Installation of performance style gear housings by Mercury Marine.
• Service replacement parts modified, changed, or superceded by Mercury Marine.
Owner Responsibility
The owner/operator is required to have engine maintenance performed to maintain emission levels within prescribed
certification standards.
The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emission levels to
exceed their predetermined factory specifications.
Single engine exceptions may be allowed with permission from the EPA for racing and testing.
90-8M0060785 DECEMBER 2011 Page 3D-3

Emissions
EPA Emission Regulations

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

The certification label must be placed on each engine at the time of manufacture and must be replaced in the same location if
damaged or removed. Shown below is a typical certification label and is not representative of any one model. Label shown
below is not to scale.
EMISSION CONTROL
a INFORMATION
f a- Idle speed
THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA
g b- Engine horsepower
b
REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE,
SPECIFICATIONS, AND ADJUSTMENTS c- Piston displacement
c IDLE SPEED (in gear): FAMILY:
h d- Engine power in kilowatts
hp L HC+NOx:FEL: g/kWh
d e- Date of manufacturer
kw CO FEL: g/kWh
i
f- Family number
SPARK PLUG:
GAP:
e LOW PERM/HIGH PERM: j g- Regulated emissions limit for the engine family
43210
h- Regulated emissions limit for the engine family
i- Recommended spark plug and gap
j- Percent of fuel line permeation
Service Replacement EPA Decal

IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine outboards have a visible and legible
emission certification decal. If this decal is missing or damaged, contact Mercury Marine Service for a replacement.
Removal
Remove all remaining pieces of the damaged or illegible decal. Do not install the new decal over a damaged old decal. Use a
suitable solvent to remove any traces of the old decal adhesive from the display location.
NOTE: If the original decal surface is in good condition, it is acceptable to clean the surface and apply the new decal over the
original.
Page 3D-4 90-8M0060785 DECEMBER 2011

Emissions
Date Code Identification

Cut and remove a "V" notch through the month of engine manufacture before installing the new decal. The month of
manufacture can be found on the old decal. If the decal is missing or the date code illegible, contact Mercury Marine Technical
Service for assistance.
Emission Control a - "V" notch

Information b - Month of
manufacture
THIS ENGINE CONFORMS TO (YEAR) CALIFORNIA AND U.S. EPA
REFER TO OWNERS MANUAL FOR MAINTENANCE,
SPECIFICATIONS, AND ADJUSTMENTS
IDLE SPEED (in gear): XXX RPM FAMILY: -----.XXXXXX
XXX HP XXXX cc FEL: XX.XXXX g/kWh
TIMING (IN DEGREES): XXXXXXXXX
PART NO. SPARK PLUG: XXXXXXXX
37-XXXXXX GAP: X.X MM (X.X IN.)
COLD VALVE INTAKE: 0.XX - 0.XX MM
CLEARANCE (mm) EXHAUST: 0.XX - 0.XX MM
JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC b
a 11184
Installation
Apply the decal on a clean surface in the original factory location.
90-8M0060785 DECEMBER 2011 Page 3D-5

Emissions
Notes:
Page 3D-6 90-8M0060785 DECEMBER 2011

Cylinder Block/Crankcase
Powerhead
Section 4A - Cylinder Block/Crankcase
Table of Contents
Cylinder Block/Crankcase Specifications...........................4A-2 Measuring Piston...................................................... 4A-46
Top Cowl Components...................................................... 4A-4 Measuring Connecting Rod ..................................... 4A-48
Lower Cowl Components...................................................4A-6 Measuring Crankshaft...............................................4A-49
Cylinder Block Components...............................................4A-8 Oil Pump .................................................................. 4A-50
Crankshaft, Connecting Rod, Piston, Timing Chain Balance Shaft...................................................................4A-52
Components................................................................. 4A-10
Flywheel and Cover Components....................................4A-12
Balance Shaft System Disassembly......................... 4A-52
Balanced Shaft System Assembly............................4A-53 4
Exhaust Manifold............................................................. 4A-14
Cylinder Head.................................................................. 4A-16
Powerhead Assembly...................................................... 4A-55
Cylinder Block Galley Plug Installation..................... 4A-55 A
Lower Cowl...................................................................... 4A-18 Crankshaft Installation.............................................. 4A-56
Lower Cowl Removal................................................4A-18 Piston/Connecting Rod Assembly............................ 4A-60
Lower Cowl Installation.............................................4A-21 Piston Ring Installation............................................. 4A-61
Dressed Powerhead Removal ........................................ 4A-27 Connecting Rod Bearing Grade Selection................4A-62
Removing Powerhead Components................................ 4A-31 Piston Connecting Rod Assembly Installation.......... 4A-64
Flywheel Removal.................................................... 4A-31 Balance Shaft Assembly Installation.........................4A-66
Wire Harness Removal.............................................4A-33 Bedplate Cover Installation.......................................4A-71
Component Removal................................................ 4A-36 Cylinder Head Installation.........................................4A-71
Powerhead Diasssembly ................................................ 4A-40 Crankshaft Seal Installation...................................... 4A-77
Cylinder Head Removal............................................4A-40 Oil Pump Installation.................................................4A-79
Cylinder Block Disassembly and Crankshaft Removal Installing Powerhead Components.................................. 4A-81
.............................................................................. 4A-42 Component Installation............................................. 4A-81
Cleaning, Inspection, and Repair.....................................4A-45 Wire Harness Installation..........................................4A-86
Powerhead Preassembly Cleaning Powerhead Installation onto the Midsection.................... 4A-90
Recommendations................................................ 4A-45 Engine Break‑in Procedure..............................................4A-97
Measuring Cylinder Bore.......................................... 4A-45
90-8M0060785 DECEMBER 2011 Page 4A-1


Compression ratio 9.5:1
Standard bore finished hone 101.609 mm (4.0 in.)
Stroke 92.00 mm (3.62 in.)
Cylinder deck
Crankcase deck
Cylinder bore maximum taper (service) 0.030 mm (0.0011 in.)
Cylinder bore maximum out of round (service) 0.050 mm (0.0019 in.)
A 60.989–60.997 mm (2.4011–2.4014 in.)
Cylinder block main bearing journal
B 60.998–61.005 mm (2.4014–2.4017 in.)
(letter)
C 61.006–61.013 mm (2.4018–2.4020 in.)
Crankshaft main bearing journal A 55.993–56.001 mm (2.2044–2.2047 in.)

(letter) B 55.985–55.993 mm (2.2041–2.2044 in.)
C 53.330–53.339 mm (2.0996–2.0999 in.)
Crankshaft connecting rod journal
D 53.321–53.329 mm (2.0992–2.0995 in.)
Crankshaft end play 0.0254–0.2794 mm (0.001–0.011 in.)
Crankshaft runout 0.05 mm (0.0019 in.)
Crankshaft main bearing oil clearance 0.052–0.086 mm (0.002–0.0033 in.)
Connecting rod piston pin bore diameter 22.016–22.026 mm (0.8667–0.8671 in.)
Journal grade "I" 56.508–56.514 mm (2.2247–2.2249 in.)
Connecting rod crankshaft pin diameter
Journal grade "0" 56.514–56.520 mm (2.2249–2.2251 in.)
Connecting rod bearing oil clearance 0.052–0.082 mm (0.002–0.0032 in.)
Piston skirt standard diameter 101.563–101.578 mm (3.9985–3.9991 in.)
Minimum 0.022 mm (0.0008 in.)
Piston to cylinder clearance
Maximum 0.046 mm (0.0018 in.)
Piston pin bore diameter 22.002–22.007 mm (0.8662–0.8664 in.)
Piston pin diameter 21.996–22.001 mm (0.8659–0.8661 in.)
First 1.520–1.545 mm (0.0598– 0.0608 in.)
Piston ring groove width Second 1.530–1.555 mm (0.0602– 0.0612 in.)
Third 3.0–3.025 mm (0.1181–0.1190 in.)
First 1.5 mm (0.059 in.)
Piston ring thickness
Second 1.5 mm (0.059 in.)
First 0.02–0.045 mm (0.0007–0.0017 in.)
Piston ring side clearance
Second 0.03–0.055 mm (0.0011–0.0021 in.)
First 0.25–0.40 mm (0.0098–0.0157 in.)
Piston ring end gap Second 0.46–0.66 mm (0.0181–0.0259 in.)
Third (lower ring only) 0.25–0.76 mm (0.0098–0.0299 in.)
Page 4A-2 90-8M0060785 DECEMBER 2011


Water pump indicator hose plastic fitting threads, block water
Loctite 567 PST Pipe temperature sensor threads
9 92-809822
Sealant Oil pressure sensor threads
Plastic elbow threads
Ground screw
Ground on cylinder block, fusible link connection on alternator
25 Liquid Neoprene 92- 25711 3
Starter solenoid exciter terminal
Negative battery cable connection on starter
66 Loctite 242 Threadlocker Tensioner guide screw threads 92-809821
Oil pump seal lips
Engine Coupler Spline
91 Crankshaft seal lip 92-802869A 1
Grease
Oil pump seal lip and oil pump gerotor drive flats
Smooth side of center main thrust bearing
95 2-4-C with PTFE 92-802859A 1
Crankshaft O-ring
135 Three Bond 1217F Bedplate cylinder block seal area 92-858005K02
M8 x 50 flange head screw threads
Piston pin
136 Lubriplate SPO 255 Rod cap screw threads and under the screw head Obtain Locally
Balance shaft tensioner assembly and tensioner spring
Timing chain tensioner assembly
Oil pump
Piston ring grooves
Synthetic Blend 4-Stroke Piston and rings
139 92-858052K01
Outboard Oil 25W-40 Cylinder bore
Flange head of shoulder screw
Camshaft gear screw threads and flange head
Special Tools
Flywheel Holding Tool 91‑ 52344
Holds and/or turns the flywheel while making engine repairs, also used to torque
the flywheel or the engine coupler.
4738
Removes flywheel from engine. Used for lifting powerhead/engine.

14869

Used to clamp high pressure (Oetiker ®) hose clamps. Part of Clamp Tool Kit
39648 (91‑803146A4).
90-8M0060785 DECEMBER 2011 Page 4A-3

Top Cowl Components
3 6
2
4
48977
Page 4A-4 90-8M0060785 DECEMBER 2011

Top Cowl Components

Torque
1 1 Top cowl assembly
2 1 Striker assembly
3 2 Screw (M6 x 16) 10 88.5
4 1 Latch
5 4 Screw (M6 x 12) 10 88.5
6 4 Washer
90-8M0060785 DECEMBER 2011 Page 4A-5

Lower Cowl Components

1
36
22 34
21
35
39 33
25
27 18 31
28 26 30
23 20 19
13 12
24 6
38
11
37
17
10
3
4 16 16
9 29
8 14
15
7 7
6 32
6
2
5
48971
6
Page 4A-6 90-8M0060785 DECEMBER 2011

Lower Cowl Components

Torque
1 1 Top cowl seal
2 1 Starboard lower cowl
3 1 Ingress mounting plate
4 2 Screw (M5 x 8) 8 70.8
5 1 Port lower cowl
6 8 Screw (M6 x 25) 10 88.5
7 2 Chap support
8 1 Hose rigging adapter
9 1 Ingress grommet
10 1 Trim harness grommet
11 1 Lower front cowl
12 1 Top cowl latch
13 2 Screw (M6 x 16) 10 88.5
14 1 Port upper mount cover
15 1 Starboard upper mount cover
16 2 Screw (M6 x 25) 10 88.5
17 1 Screw (M6 x 50) 10 88.5
18 1 Rear panel assembly
19 2 Latch
20 1 Retainer
21 1 Latch handle
22 1 Icon
23 1 Link
24 1 Pin
25 2 Screw (M6 x 25) 10 88.5
26 2 Bushing
27 2 Washer
28 1 Seal
29 1 Trim sensor harness grommet
30 1 Trim switch bezel
31 1 Retainer
32 1 Plug
33 1 Seal
34 1 Fitting
35 1 Washer
36 1 Tether
37 1 Screw (M6 x 50) 10 88.5
38 1 Screw (M6 x 20) 10 88.5
39 2 Screw (M6 x 25) 10 88.5
90-8M0060785 DECEMBER 2011 Page 4A-7

Cylinder Block Components

14
12
13
17 18
5
4 9
11
2 15
3 16 6
1
10
7 3
19
20 22 3
8
23
21
48986
Page 4A-8 90-8M0060785 DECEMBER 2011

Cylinder Block Components

Torque
1 1 Cylinder block
2 1 Bedplate
3 4 Dowel pin
First 15 132.7
4 10 Screws (M10 x 95) Second 40 29.5
Final Turn addtional 60°
5 1 Dipstick
6 2 O‑ring
7 1 Plug (18 mm) 22 194.7
8 1 Plug (30 mm) 55 40.5
9 12 Screw (M6 x 25) 10 88.5
10 1 Plug (24 mm) 55 40.5
11 12 Screw (M8 x 50) 35 25.8
12 1 Bedplate cover
13 1 Bedplate cover seal
14 1 Oil fill cap
15 1 Thermostat
16 1 O‑ring
Torque sequence specific: refer to
17 7 Screw (M8 x 95)
Balance Shaft Assembly Installation
18 1 Balance shaft assembly
19 1 Oil pump
20 4 Screw (M6 x 45) 10 88.5
21 1 Oil pickup tube assembly
22 2 Metal hose clamp (39.6 mm)
23 1 Hose
90-8M0060785 DECEMBER 2011 Page 4A-9

Crankshaft, Connecting Rod, Piston, Timing Chain Components

3
4
25 24
9 23
22
10
2
19 21
11
1
3
13 20
18
17
12 16
6
7
14 48992
15
Page 4A-10 90-8M0060785 DECEMBER 2011

Crankshaft, Connecting Rod, Piston, Timing Chain Components

Torque
1 4 Piston assembly
2 4 Piston ring set
3 8 Circlip
4 4 Wrist pin
5 4 Connecting rod
6 4 Rod cap
First 10 88.5
7 8 Rod cap screw Second 25 18.4
Final Turn additional 90°
8 4 Connecting rod bearing set
9 1 Retaining ring
10 1 Crankshaft seal
11 1 Spacer
12 1 Crankshaft
13 Sprocket (NSS)
14 1 O‑ring seal
15 5 Main bearing set
16 1 Balance shaft chain
17 2 Screw (M6 x 20) 10 88.5
18 2 Washer
19 1 Fixed chain guide
20 2 Screw (M6 x 30) 10 88.5
21 1 Tensioner assembly
22 2 Screw (M8 x 25) 14 124
23 1 Tensioner bracket
24 1 Plug (10 mm)
25 1 Spacer (NSS)
90-8M0060785 DECEMBER 2011 Page 4A-11

Flywheel and Cover Components

1
3
4
1
48978
Page 4A-12 90-8M0060785 DECEMBER 2011

Flywheel and Cover Components

Torque
1 3 Flange head screw (M6 x 13) 10 88.5
2 1 Flywheel cover
First 100 73.7
3 1 Flywheel screw (M20 x 68)
Final 200 147.5
4 1 Washer
5 1 Flywheel assembly
6 1 Flywheel key
90-8M0060785 DECEMBER 2011 Page 4A-13

Exhaust Manifold
1
2
5
3
6
3
49256
Page 4A-14 90-8M0060785 DECEMBER 2011

Exhaust Manifold
Torque
1 1 Gasket
2 1 Manifold
3 2 Plug (18 mm)
4 1 Plug (Legris fitting optional)
First 15 132.7
5 9 Screw (M8 x 60)
Final 28 20.6
6 1 Cover
7 4 Plastic screws
90-8M0060785 DECEMBER 2011 Page 4A-15

Cylinder Head
6
49000
Page 4A-16 90-8M0060785 DECEMBER 2011

Cylinder Head
Torque
1 12 Screw (M6 x 25) 10 88.5
2 1 Camshaft cover
3 1 Seal
First 15 132.7
4 10 Screw (M10 x 95) Second 30 22.1
5 3 Screw (M6 x 40) 10 88.5
6 1 Gasket
90-8M0060785 DECEMBER 2011 Page 4A-17

Lower Cowl
Lower Cowl Removal
! WARNING
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.
1. Disconnect the battery cables from the battery.

2. Remove the fuel line, remote control harness, the throttle cable, and the shift cable.
3. Locate the trim motor harness connectors, trim sender harness connector, and the cowl trim switch harness connector on
the port side of the engine and disconnect them.
a - Trim motor harness connectors

b - Trim sender harness connector
c - Cowl trim switch harness connector
b c
48017
4. Remove the grommets securing the trim motor wire harness and trim sender wire harness to the cowls. Remove the
harnesses from the cowls.
a - Trim motor wire harness grommet

b - Trim sender wire harness grommet
a b
48024
Page 4A-18 90-8M0060785 DECEMBER 2011

5. Rotate the fresh water flush retainer counterclockwise to remove it from the cowl.
48018
6. Remove the fresh water flush hose adapter from the retainer.
7. Remove the fresh water flush retainer.
a - Fresh water flush hose adapter

a b - Tether
c - Fresh water flush retainer
c
b
48020
8. Remove the three screws securing the front cowl latch catch.
a - Screw (M6 x 16) (2)

b - Screw (M6 x 20)
a
48021
9. Remove the screw securing the lower front cowl to the starboard cowl.
90-8M0060785 DECEMBER 2011 Page 4A-19

10. Remove the cowl seal from the port lower cowl all the way past the rear cowl latch.
a - Screw securing the lower front cowl

b - Cowl seal
a
48022
11. Remove the port side screw securing the cowl latch attachment to the port cowl.
12. Loosen several turns out the starboard side screw securing the cowl latch attachment to the starboard cowl.
NOTE: The starboard side screw should remain attached to prevent the cowl latch attachment from dropping to the floor
during the cowl removal process.
a - Port side screw (remove)

b b - Starboard side screw (loosen)
a
48023
13. Remove three screws securing the front of the port side cowl to the starboard side cowl.
14. Remove the lower screw securing the rear of the port side cowl to the starboard side cowl.
15. Remove the upper screw securing the rear of the port side cowl to the starboard side cowl. This screw also retains the rear
cowl latch attachment.
a - Screws securing the front of the

cowls (3)
b - Screw securing the lower rear of the
cowls
c - Screw securing the upper rear of the
cowls
a
48026
Page 4A-20 90-8M0060785 DECEMBER 2011

16. Remove the inside screw securing the port side cowl to the starboard side cowl.
NOTE: Use the cowl fresh water flush attachment opening to access the inside screw.
48027
17. Remove the port side cowl.

18. Remove the screw securing the rear cowl latch attachment to the starboard cowl and remove the attachment.
48028
19. Secure the bottom of the cowl from scraping the oil drain valve and pull on the upper part of the cowl to remove it from the
cowl seal.
a - Oil drain valve
a
48029
Lower Cowl Installation

1. Lubricate the cowl seal with liquid detergent. Do not use a petroleum based product to lubricate the cowl seal.
90-8M0060785 DECEMBER 2011 Page 4A-21

2. Guide the port side cowl over the oil drain valve and install the cowl onto the cowl seal.
a - Oil drain valve
a
48029
3. Ensure the cowl is aligned with the upper mount cover. Use a round piece of metal stock to help align the covert with the
cowl. Use caution not to damage the cowl or cover.
48030
4. Install the lower front cowl to the starboard cowl and secure with a M6 x 25 flange head screw. Do not tighten the screw.
a - Lower front cowl

b - Flange head screw (M6 x 25)
48031
Page 4A-22 90-8M0060785 DECEMBER 2011

5. Install the rear cowl latch attachment onto the cowl seal and the muffler exhaust port. Secure the rear cowl latch
attachment onto the port side cowl with a M6 x 25 flange head screw. Do not tighten the screw.
b
a
d
c
48032
a- Muffler exhaust port

b- Muffler exhaust port grommet
c- Cowl seal
d- Flange head screw (M6 x 25)
6. Install the port side cowl onto the cowl seal. Ensure the cowl is aligned with the upper mount cover. Use a round piece of
metal stock to help align the covert with the cowl if necessary. Use caution not to damage the cowl or cover.
48034
7. Secure the port side cowl to the starboard side cowl with a M6 x 50 flange head screw. Do not tighten the screw.
48027
8. Secure the rear of the port side cowl and the rear cowl latch attachment to the starboard side cowl with a M6 x 85 flange
head screw. Do not tighten the screw.
90-8M0060785 DECEMBER 2011 Page 4A-23

9. Secure the lower rear of the port side cowl to the starboard side cowl with a M6 x 25 flange head screw. Do not tighten the
screw.
10. Secure the front of the port side cowl to the starboard side cowl with three M6 x 25 flange head screws. Do not tighten the
screws.
a - Flange head screws (M6 x 25) (3)

b - Flange head screws (M6 x 25)
c - Flange head screw (M6 x 85)
48026
11. Secure the cowl latch attachment to the port cowl with a M6 x 25 flange head screw. Do not tighten the screw.
a - Flange head screw (M6 x 25)
48035
12. Secure the front cowl attachment to the port cowl with a M6 x 25 flange head screw.
a - M6 x 25 flange head screw
48036
13. Verify all of the cowl mating components are properly aligned.
14. Tighten all of the cowls M6 screws to the specified torque.
Page 4A-24 90-8M0060785 DECEMBER 2011


M6 cowl screws 10 88.5
15. Starting at the center of the front cowl attachment, install the cowl seal. Use a rubber hammer to lightly tap on the seal to
ensure it is fully seated on the cowling.
16. Install the front cowl latch catch and secure with two M6 x 16 screws and one M6 x 20 screw. Tighten the screws to the
specified torque.
a - Screw (M6 x 16) (2)

b - Screw (M6 x 20)
a
48021

Screw (M6 x 16) (2) 10 88.5
Screw (M6 x 20) 10 88.5
17. Guide the fresh water flush hose adapter through the port side cowl opening.
18. Thread the fresh water flush retainer onto the tether.
a - Fresh water flush hose adapter

a b - Tether
c - Fresh water flush retainer
c
b
48020
90-8M0060785 DECEMBER 2011 Page 4A-25

19. Install the fresh water flush retainer and rotate it clockwise to secure it to the cowl.
48037
20. Install the grommets onto the trim motor wire harness and trim sender wire harness. Guide the harnesses through the cowl
openings. Install the grommets onto the cowls.
a b
48038
a - Trim motor wire harness grommet

b - Trim sender wire harness grommet
21. Locate the trim motor harness connectors, trim sender harness connector, and the cowl trim switch harness connector on
the port side of the engine and connect them to the appropriate connector.
a - Trim motor harness connectors

b - Trim sender harness connector
c - Cowl trim switch harness connector
b c
48017
22. Install the throttle and shift cables, fuel line, and remote control harness. Refer to Section 1D ‑ Electrical, Fuel Hose, and
Control Cables.
23. Connect the battery cables.
Page 4A-26 90-8M0060785 DECEMBER 2011

Dressed Powerhead Removal

! WARNING
1. Disconnect all batteries from the engine.

2. Remove the throttle and shift cables, fuel line, and remote control harness.
3. Drain the oil from the engine. Refer to Section 1B ‑ Changing Engine Oil.
4. Remove the screw securing the muffler to the adapter plate.
5. Cut the cable tie securing the hose to the muffler. Remove the muffler from the hose.
b a - Screw
b - Cable tie
a
48054
6. Cut the cable tie securing the fuel pump connector to the manifold air temperature (MAT) sensor harness.
7. Disconnect the fuel pump connector from the engine harness.
8. Release the fuel pressure on the fuel rail. Refer to Section 3C ‑ Fuel Rail Removal and Disassembly.
! CAUTION
9. Remove the 15.7 mm metal hose clamp securing the high‑pressure fuel line to the fuel rail. Remove the high‑pressure fuel
line from the fuel rail.
10. Remove the manifold pressure reference line from the fuel supply module (FSM).
11. Remove the M6 x 25 screw securing the powerhead water dump hose fitting to the adapter plate.

a b line
c - Cable tie securing the fuel pump connector
e - Screw securing the water dump hose fitting
e c
d
48055
12. Remove the water dump hose fitting from the adapter plate. Pull the hose out to access the three powerhead mounting
screws.
90-8M0060785 DECEMBER 2011 Page 4A-27

IMPORTANT: After removing the water dump hose fitting from the adapter plate, cover the opening with a piece of tape.
48531
13. Remove the powerhead mounting screws.
48057
14. Remove the screws holding the port and starboard upper mount covers to the adapter plate. Remove the covers.
a - Screw
a b - Upper mount covers
b
48058
Page 4A-28 90-8M0060785 DECEMBER 2011

15. Remove the nut and washer securing the shift link to the shift shaft.
a - Nut and washer

a b - Shift link
48059
16. Cut the cable tie securing the hose to the water pump indicator fitting.
17. Disconnect the fuel supply hose at the fuel filter outlet port. Remove the filter and attachment from the adapter plate.
18. Remove the speedometer hose from the retainer on the shift bracket.
d a- Cable tie
b- Water pump indicator fitting
c- Fuel supply hose at the fuel filter outlet port
d- Retainer on the shift bracket
b
c
48064
19. Cut the cable ties securing the hoses to the strainer. Remove the hoses.
20. Remove the screws securing the strainer to the exhaust water jacket.
a - Cable ties securing the hoses

b - Screws securing the strainer
b
a
48068
90-8M0060785 DECEMBER 2011 Page 4A-29

21. Remove the four port side screws securing the powerhead to the adapter plate.
48071
22. Remove the five starboard side screws securing the powerhead to the adapter plate.
48070
23. Install the flywheel puller/lifting ring and secure with the screws. Tighten the screws to the specified torque.
48072

Screws 27 20
24. It may be necessary to grasp the bottom of the cam cover and pull up to remove the powerhead assembly from the
exhaust on the adapter plate.
Page 4A-30 90-8M0060785 DECEMBER 2011

25. Remove the metal hose clamp securing the oil pickup tube to the oil pump. Remove the hose from the oil pump.
a - Metal hose clamp securing the oil pickup tube
48074
Removing Powerhead Components

Flywheel Removal
1. Remove the three screws securing the flywheel cover and remove the cover.
2. Loosen the front alternator mounting screw.
3. Remove the rear alternator mounting screw.
b a - Loosen
b - Remove
a
48145
48146
90-8M0060785 DECEMBER 2011 Page 4A-31

5. Remove the alternator belt from the alternator pulley and flywheel.
48138
6. Hold the flywheel with the flywheel holding tool. Loosen the flywheel screw four turns out from a light seat.
a - Breaker bar
b - Flywheel holding tool
48149

7. Install the flywheel puller base to the flywheel with three screws. Tighten the three screws to the specified torque.
8. Thread the flywheel puller adapter into the puller base until it bottoms out.
9. Thread the flywheel puller screw into the flywheel puller adapter.
10. Tighten the flywheel puller screw until the flywheel becomes loose. Remove the flywheel.
NOTE: Do not use power tools to remove the flywheel.
IMPORTANT: Do not strike or heat the flywheel. Striking or heating the flywheel will damage the flywheel.
c
b a- Flywheel puller base
b- Puller screws
d c- Flywheel puller screw
a d- Flywheel puller adapter
48150
Page 4A-32 90-8M0060785 DECEMBER 2011


Screws (3) 27 20
Wire Harness Removal

1. Disconnect the engine harness connectors from the throttle position sensor (TPS), oil pressure sender, manifold absolute
pressure (MAP) sensor, and idle air control (IAC).
2. Remove the plastic harness retainer from the intake manifold. Do not lose the retainer.
a a- TPS
b- Oil pressure sender
b c- Plastic harness retainer
d- MAP
e- IAC
c d
48240
3. Guide the harness past the throttle body.
48241
4. Cut five cable ties securing the engine harness to the intake manifold.
5. Disconnect the engine harness connectors from the fuel injectors.
6. Cut the cable tie securing the engine harness connector to the intake manifold air temperature (MAT) sensor.
90-8M0060785 DECEMBER 2011 Page 4A-33

7. Disconnect the engine harness from the intake manifold air temperature sensor.
a - Cable tie (5)

b - Fuel injector engine harness
connectors (4)
c - Cable tie (intake manifold air
temperature sensor)
b
a
49163
8. Cut the cable tie securing the crankshaft position sensor (CPS) and cylinder block temperature sensor connectors to the
engine harness.
9. Disconnect the engine harness connectors from the crankshaft position sensor and cylinder block temperature sensor.
10. Cut the cable tie securing the water pump indicator hose to the cylinder block fitting and remove the hose from the fitting.
11. Pull the engine harness out from under the thermostat dump hose and crankcase ventilation hose.
c a- Cylinder block temperature sensor

d b- Crankshaft position sensor
c- Thermostat dump hose
d- Crankcase ventilation hose
e- Cable tie securing the water pump indicator hose
f- Cable tie securing sensor connectors
b e
a
f
48243
12. Pull the insulator boot off the alternator output wire.
13. Remove the nut securing the alternator output wire and remove the wire from the alternator.
14. Remove the engine harness alternator sense connector from the alternator.
Page 4A-34 90-8M0060785 DECEMBER 2011

15. Remove the front screw securing the alternator to the cylinder block and remove the alternator.
a - Engine harness alternator sense connector

c b - Insulator boot
c - Front screw securing the alternator
b
a
48244
16. Remove the screw securing the engine wire harness grounds to the cylinder block.
17. Remove the engine harness connectors from the ignition coils.
18. Cut the cable tie securing the engine harness to the cylinder block.
a - Screw securing the engine wire harness grounds

b - Ignition coil harness connector
a c - Cable tie securing the engine harness
48246
19. Remove the diagnostic interface harness connector from the crankcase cover.
20. Remove the vessel sensor engine harness connector from the crankcase cover.
22. Cut the cable ties securing the engine harness to the shift bracket.
a a - Diagnostic interface harness connector

b - Vessel sensor engine harness
connector
b
c - Shift position sensor connector
d - Cable ties
d
c
d 48247
90-8M0060785 DECEMBER 2011 Page 4A-35

23. Remove the screw securing the battery negative cable to the starter.
24. Remove the nut and washer securing the starter exciter wire and remove the wire.
25. Pull the insulator boot off the starter power terminal and remove the nut securing the power cable to the starter terminal.
26. Cut two cable ties securing the cables to the crankcase cover.
b c a- Screw securing the battery negative cable

b- Nut and washer securing the starter exciter wire
a c- Insulator boot
d- Cable ties
48248
27. Remove the engine harness from the harness retainer.

28. Unlatch the engine harness from the engine control unit (ECU) and remove the engine harness.
29. Remove the screws and washers securing the ECU to the crankcase cover.
a a - Harness retainer
c b - Latch securing engine harness
c - Screws and washers securing ECU
48249
30. Cut the cable tie securing the engine harness to the cylinder block below the electrical box.
31. Remove the three screws and washers securing the electrical cover to the cylinder block below the electrical box.
a - Screws and washers securing the electrical cover

b - Cable tie
b
48250
Component Removal
1. Remove the ignition wires from the coils.
Page 4A-36 90-8M0060785 DECEMBER 2011

2. Remove the screws securing the ignition coils to the cylinder block.
a - Screws securing the ignition coils

a b - Ignition wires (4)
48254
3. Remove the ignition wires from the spark plugs and remove the spark plugs.
4. Remove nine screws securing the exhaust manifold to the cylinder head and remove the exhaust manifold.
a - Screws securing the exhaust manifold

b b - Spark plug ignition wire
a
48255
5. Cut the cable tie securing the powerhead fresh water flush hose to the cylinder block.
6. Remove the flush hose threaded plastic elbow from the cylinder block.
a - Cable tie
b - Flush hose threaded plastic elbow
b
48256
7. Remove the screw securing the starter ground to the cylinder block.
90-8M0060785 DECEMBER 2011 Page 4A-37

8. Remove the screws securing the starter to the cylinder block.
a - Screw securing the starter ground

b - Screws securing the starter
48258
a
9. Remove the oil filter.
10. Remove the oil filter drip tray.
11. Remove three screws securing the shift bracket to the cylinder block.
a - Oil filter
a
b - Oil filter drip tray shoulder screws
c - Screws securing the shift bracket
c 48260
12. Remove the plastic retainers securing the manifold reference hose, thermostat dump hose, and water pump indicator hose.
a - Manifold reference hose plastic retainer

b - Water pump indicator hose plastic retainer
c - Thermostat dump hose plastic retainer
a
c
48261
13. Remove the crankcase ventilation hose adapter from the throttle body.
Page 4A-38 90-8M0060785 DECEMBER 2011

14. Remove 11 screws securing the intake manifold to the cylinder head and cylinder block, and remove the intake manifold.
a - Crankcase ventilation hose adapter

b - Screws securing the intake manifold
a
b
b
48263
15. Remove the two screws securing the thermostat housing to the cylinder block. Remove the thermostat housing.
48264
16. Remove the plastic retainers securing the hose to the cylinder block.
17. Remove the oil pressure sensor.
a - Oil pressure sensor

a b - Plastic retainers securing the hose
48266
18. Remove the water pump indicator hose plastic fitting from the cylinder head.
19. Remove the block water temperature sensor from the cylinder block.
90-8M0060785 DECEMBER 2011 Page 4A-39

20. Remove the two screws securing the crankshaft position sensor to the cylinder block.
a - Water pump indicator hose plastic fitting

b - Block water temperature sensor
c - Crankshaft position sensor
b c
a
48267
Powerhead Diasssembly
Cylinder Head Removal
1. Remove 12 screws securing the cam cover to the cylinder head.
48293
2. Remove the two screws securing the timing chain tensioner cover.
NOTE: The timing chain tensioner will exert a constant force when removing the cover screws.
48294
3. Secure the camshaft hex with a wrench and rotate the camshaft so the camshaft gear timing mark is at the 9 o'clock
position.
NOTE: If the camshaft gear timing mark cannot be identified, the camshaft gear pin can also be used for the 9 o'clock
position.
4. Remove the camshaft gear retaining screw and remove the gear.
Page 4A-40 90-8M0060785 DECEMBER 2011

IMPORTANT: The camshaft gear retaining screw is left‑hand thread.
a - Camshaft gear timing mark

b - Camshaft gear pin
c - Camshaft gear retaining screw (left‑hand thread)
a
b
c
48295
5. Remove the three small screws at the bottom of the cylinder head.
48296
6. Loosen the M10 x 95 screws 1/4 turn in the sequence shown. Perform the 1/4 turn sequence twice and then remove the
screws. The cylinder head can be removed.
4 8 10 6
2
3 7 9 5 1 48297
90-8M0060785 DECEMBER 2011 Page 4A-41

Cylinder Block Disassembly and Crankshaft Removal

1. Remove four screws securing the oil pump to the cylinder block.
48411
2. Remove the screws securing the chain guides and remove the chain guides.
3. Remove the chain from the crankshaft.
48412
4. Remove 10 screws securing the cover to the cylinder block. Remove the cover.
48413
5. Push the balance shaft assembly drive chain tensioner in with a pry bar or other tool.
6. Insert a ridged piece of wire into the drive chain tensioner lockout. A large paper clip works well as a ridged piece of wire.
Page 4A-42 90-8M0060785 DECEMBER 2011

IMPORTANT: The wire should be long enough so not to be overlooked during the engine assembly process.
c a- Balance shaft assembly

b b- Pry bar
c- Drive chain tensioner
d- Ridged piece of wire
a
d
48414
7. Remove the two screws securing the balance shaft assembly chain guide to the cylinder block. Remove the chain guide.
a - Screws (2)
b b - Ridged piece of wire
a
48493
8. Remove seven screws securing the balance shaft assembly to the cylinder block.
9. Lift the balance shaft assembly from the dowel pins.
10. Remove the balance shaft chain from the balance shaft assembly gear.
48416
11. Use a clean cloth and a mild solvent to remove any oil from the connecting rod caps.
12. Identify each connecting rod cap location with indelible ink.
90-8M0060785 DECEMBER 2011 Page 4A-43

13. Loosen the rod cap screws 1/4 turn each before removing them completely. Remove the rod cap. Verify the bearing is on
the rod cap and not on the crankshaft journal.
48417
a - Rod cap screws (2 each)

b - Identification for connecting rod location
14. Push the connecting rod assembly out of the cylinder block bore and install the connecting rod cap. Secure the cap with
the rod cap screws. Remove the remaining connecting rods and pistons.
15. Loosen the 12 perimeter screws 1/4 turn each.
16. Loosen the 10 main bearing screws 1/4 turn each.
a - Main bearing screws

(10)
b - Perimeter screws (12)
b
48419
17. Remove all of the screws.
Page 4A-44 90-8M0060785 DECEMBER 2011

18. Use the pry locations on both sides of the powerhead to break the bedplate seal and remove the bedplate.
48415
19. Remove the crankshaft from the cylinder block. Secure the crankshaft in a fixture so it will not be damaged.
20. Remove the main bearings from the cylinder block and crankcase cover. The bearings are matched sets and cannot be
intermixed. Identify where each bearing set was installed.
21. Remove the 24 mm oil galley plug on the top of the cylinder block. Remove the O‑ring and discard.
22. Remove the 18 mm oil galley plug near the oil filter mounting location. Remove the O‑ring and discard.
23. Remove the 30 mm oil galley plug on the bottom of the cylinder block. Remove the O‑ring and discard.
a - 24 mm oil galley plug

b - 18 mm oil galley plug
a c c - 30 mm oil galley plug
b 48443
Cleaning, Inspection, and Repair

Powerhead Preassembly Cleaning Recommendations
IMPORTANT: Any threaded hole or bolt with threadlocking compound that is contaminated with oil, must be thoroughly cleaned
with a solvent to remove all traces of oil contamination. Failure to remove oil contamination will result in poor threadlocking
compound adhesion.
Prior to assembling the powerhead, all threaded holes on the cylinder head and cylinder block must be cleared of threadlocking
compound dust. Use compressed air to clear threadlocking compound dust.
Wash the cylinder block and crankcase cover with hot soapy water to remove debris and honing compound. Dry the cylinder
block with compressed air. Failure to thoroughly clean the cylinder block of honing compound and/or debris will result in
premature engine failure.
Measuring Cylinder Bore

Measure the cylinder walls for taper, out of round, or excessive ridge at the top of the ring travel. This should be done with a
cylinder bore dial indicator or an inside micrometer. 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.
90-8M0060785 DECEMBER 2011 Page 4A-45

The measurement for cylinder taper should be taken at three depth locations: 20 mm (0.8 in.), 60 mm (2.4 in.), and 100 mm
(3.9 in.).
a - 100 mm (3.9 in.)

b - 60 mm (2.4 in.)
c - 20 mm (0.8 in.)
c
b
a
3129
Cylinder Bore Specification

Standard finished hone 101.609 mm (4.00 in.)
Maximum taper (service) 0.030 mm (0.0011 in.)
Maximum out of round (service) 0.050 mm (0.0019 in.)
Measuring Piston
Inspect piston wall for wear or damage. Replace piston if necessary.
Piston Diameter
1. Measure the piston at a point 16 mm (0.63 in.) from the bottom, 90° to the piston pin. Replace piston if out of specification.
a a - Piston skirt diameter

b b - Measure point 16 mm (0.63 in.)
22022
Piston
Skirt diameter 101.563–101.578 mm (3.9985–3.9991 in.)
2. Measure piston to cylinder clearance. If out of specification, examine piston and cylinder bore further to determine repair/
replacement.
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 Clearance

Minimum clearance 0.022 mm (0.0008 in.)
Maximum clearance 0.046 mm (0.0018 in.)
Piston Ring Groove

Measure piston ring groove. Replace the piston if out of specification.
a - First ring groove

a b - Second ring groove
c - Third ring groove (oil)
b
c 22410
Page 4A-46 90-8M0060785 DECEMBER 2011

Piston Ring Groove

First "a" 1.520–1.545 mm (0.0598–0.0608 in.)
Second "b" 1.530–1.555 mm (0.0602–0.0612 in.)
Third "c" 3.0–3.025 mm (0.1181–0.1190 in.)
Piston Ring Side Clearance

Measure the first and second piston ring side clearance. The side clearance for the third ring (oil) is not a valid measurement
because of ring movement during the measurement process. Replace piston rings as a set if out of specification.
a a - First ring
b - Second ring
b c - Third ring (oil)
c
48804
Piston Ring Side Clearance

First "a" 0.02–0.045 mm (0.0007–0.0017 in.)
Second "b" 0.03–0.055 mm (0.0011–0.0021 in.)
Piston Ring End Gap

Measure piston ring end gap clearance. Replace piston rings as a set if out of specification.
NOTE: Ring must be level for measurement. Push ring 25.4 mm (1.0 in.) into bore with crown of piston.
a - 25.4 mm (1.0 in.)
22024
Piston Ring End Gap

First 0.25–0.40 mm (0.0098–0.0157 in.)
Second 0.46–0.66 mm (0.0181–0.0259 in.)
Third (lower oil ring only) 0.25–0.76 mm (0.0098–0.0299 in.)
90-8M0060785 DECEMBER 2011 Page 4A-47

Piston Pin Bore Diameter

Measure the piston pin bore diameter. Replace the piston if out of specification.
22025
Piston Pin
Bore diameter 22.002–22.007 mm (0.8662–0.8664 in.)
Piston Pin
Measure the piston pin diameter. Replace the piston pin if out of specification.
22026
Piston Pin
Diameter 21.996–22.001 mm (0.8659–0.8661 in.)
Measuring Connecting Rod

1. Secure the connecting rod in a soft jaw vice.
2. Verify the rod cap alignment and tighten the screws in three stages to the specified torque.

First 10 88.5
Rod cap screws Second 25 18.4
3. Measure the small (piston pin) and large (crankshaft journal) ends of the connecting rod.
a a - Crankshaft journal end

b b - Piston pin end
47983
Page 4A-48 90-8M0060785 DECEMBER 2011

4. Compare the connecting rod journal measurement with the journal code specifications listed in the following chart. If the
connecting rod journal measurement does not match the stamped connecting rod journal code, replace the connecting rod.
a - Stamped connecting rod journal code "I"

b - Stamped connecting rod journal code "0"
a b
0
47985
Connecting Rod
22.016–22.026 mm
Piston pin bore
(0.8667–0.8671 in.)
56.508–56.514 mm
Journal code "I"
(2.2247–2.2249 in.)
56.514–56.520 mm
Journal code "0"
(2.2249–2.2251 in.)
Measuring Crankshaft
Crankshaft Runout
1. Thoroughly clean crankshaft and inspect bearing surfaces. Replace crankshaft if bearing surfaces are pitted, scored, or
discolored.
2. Measure runout on all of the main bearing journals. Replace crankshaft if out of specification.
3. Clean oil holes in crankshaft.
47987
Crankshaft
Runout limit 0.05 mm (0.0019 in.)
Crankshaft Main Bearing and Crankshaft Journal Measurement

1. Measure the five main bearing journal diameters and record the measurement.
2. Measure the crankshaft journal diameters and record the measurement.
a
a - Crankshaft journals
b - Main bearing journals
47988
b
90-8M0060785 DECEMBER 2011 Page 4A-49

3. Locate the main bearing journal code on cylinder number one top counterweight. Compare the journal code with your
recorded measurements. If the measurements do not match the journal specifications, replace the crankshaft.
a - Main bearing journal code

b - Crankshaft journal code
48421
Crankshaft Journal Specifications

Description Dimension Code
55.993–56.001 mm (2.2044–2.2047 in.) A
Main bearing journal
55.985–55.993 mm (2.2041–2.2044 in.) B
53.330–53.339 mm (2.0996–2.0999 in.) C
Crankshaft journal
53.321–53.329 mm (2.0992–2.0995 in.) D
Oil Pump
Disassembly and Inspection
The oil pump is not a serviceable part, but should be disassembled for inspection when the cylinder head or cylinder block is
repaired. The oil pump should also be disassembled and inspected if the engine was submerged in water.
1. Remove the seven screws securing the oil pump cover to the oil pump housing. Remove the cover.
48353
Page 4A-50 90-8M0060785 DECEMBER 2011

2. Remove the inner drive gerotor and outside gerotor.
b a - Inner drive gerotor

b - Outside gerotor
a
46329
3. Inspect all areas where the gerotors contact each other and where the gerotors contact the oil pump housing and cover.
The contact areas should be smooth without grooves, galling, or evidence of corrosion.
4. A pressure relief valve is incorporated into the oil pump housing. It should never be removed from the housing to modify
the spring pressure. If significant debris was found in the oil pump gerotor area, the oil pump must be replaced as an
assembly.
Assembly
1. Wash the housing, cover, and gerotors with a mild solvent. Use compressed air to dry the components.
2. Inspect the seal lips for damage. Replace as needed. Lubricate the seal lips with Engine Coupler Spline Grease.

91 Oil pump seal lips 92-802869A 1
Grease
3. Generously lubricate the gerotors and the areas where the gerotors contact the housing and cover with Synthetic Blend
4‑Stroke Outboard Oil 25W‑40.

Synthetic Blend 4-Stroke
139 Oil pump 92-858052K01
Outboard Oil 25W-40
4. Install the outside gerotor into the oil pump housing with the dot side up.
5. Install the inner drive gerotor with the dot side up.

b - Outside gerotor
a
46329
6. Align the oil pump cover with the oil pump housing pins and install the oil pump cover.
90-8M0060785 DECEMBER 2011 Page 4A-51

7. Secure the oil pump cover with seven screws. Tighten the screws to the specified torque in the sequence shown.
4
3
1
5
2
46327
6

Oil pump cover screws (7) 4 35.4
Balance Shaft
Balance Shaft System Disassembly
IMPORTANT: The balance shaft assembly is not serviceable but should be disassembled to inspect the balance shaft bearings
and journals for damage.
1. Remove two M8 x 60 flange head screws securing the balance shaft top housing to the bottom housing.
47740
2. Remove the long and short balance shafts from the bottom housing.
a - Long balance shaft

a b - Short balance shaft
47745
Page 4A-52 90-8M0060785 DECEMBER 2011

3. Inspect the bearings for damage.
47741
Balance Shaft Disassembly

NOTE: The balance shaft drive gear should not be removed unless the gear must be replaced.
1. Use a 30 mm wrench to secure the balance shaft and remove the M8 x 50 flange head screw securing the balance shaft
drive gear.
2. Remove the balance shaft drive gear. It may be necessary to use a soft face mallet to remove the drive gear.
a a - 30 mm wrench
b - Balance shaft drive gear
c - M8 x 50 flange head screw
47750
Balanced Shaft System Assembly

1. Verify the balance shaft drive gear and the balance shaft mating surfaces are clear of contamination. Clean with a mild
solvent and dry with compressed air.
2. Install the balance shaft drive gear.
3. Lubricate the M8 x 50 flange head and screw threads with Lubriplate SPO 255 and secure the balance shaft drive gear
with the screw.

136 Lubriplate SPO 255 M8 x 50 flange head screw threads Obtain Locally
90-8M0060785 DECEMBER 2011 Page 4A-53

4. Use a 30 mm wrench to secure the balance shaft and tighten the flange head screw to the specified torque.
a a - 30 mm wrench
b - Balance shaft drive gear
c - M8 x 50 flange head screw
47750

M8 x 50 flange head screw 80 59
5. Verify the bottom housing is clear of debris on all contact surfaces.

6. Lubricate the bearings and the thrust face of the bottom housing with a generous amount of engine assembly lubricant.
Engine assembly lubricant can be purchased locally.
47794
7. Lubricate the balance shafts bearing contact area, the thrust face area, and the gear teeth with engine assembly lubricant.
47796
Page 4A-54 90-8M0060785 DECEMBER 2011

8. Align the balance shaft timing marks and carefully install the balance shafts onto the bottom housing.
a - Timing marks
47795
9. Install the top housing onto the bottom housing.

10. Secure the balance shaft top housing to the bottom housing with two M8 x 60 flange head screws. Tighten the screws to
47740

M8 x 60 flange head screws (2) 8 70.8
Powerhead Assembly
Cylinder Block Galley Plug Installation
1. Install new O‑rings onto the galley plugs.
2. Install the galley plug in their appropriate locations and tighten to the specified torque.
a - 24 mm oil galley plug

b - 18 mm oil galley plug
a c c - 30 mm oil galley plug
b 48443
90-8M0060785 DECEMBER 2011 Page 4A-55


24 mm oil galley plug 55 40.5
Crankshaft Installation
Crankshaft Main Bearing Selection
1. Locate the main bearing code on the starboard side of the cylinder block.
a - Cylinder block main

bearing code
a
48444
2. Locate the main bearing journal code on the crankshaft top counterweight.

48421
3. Select the main bearing color for each main bearing journal. Refer to the following chart.
Crankshaft Journal Code Cylinder Block Code Bearing Color Selection

A A Green
A B Blue
A C White
B A Blue
B B White
B C Orange
Crankshaft Installation
1. Verify the cylinder block and the bedplate main bearing locations are clear of debris and contamination.
2. Verify the main bearing selection is correct.
3. Install the selected main bearings with the oil groove onto the cylinder block. Install the selected main bearings without the
oil grooves onto the bedplate.
IMPORTANT: Each matched bearing set has one bearing half without an oil groove and one with an oil groove, The
bearing half with the oil groove must be installed onto the cylinder block main bearing. Failure to install the bearing half
with the oil groove onto the cylinder block main bearing, will cause a no lubrication condition for that main bearing, and will
result in a catastrophic engine failure.
Page 4A-56 90-8M0060785 DECEMBER 2011

4. Apply 2‑4‑C with PTFE to the smooth side of the center main thrust bearings.
5. Install the center main thrust bearings onto the bedplate. Verify the smooth surface of the thrust bearing is against the
cylinder block.
a - Center main bearing on bedplate (without

oil groove)
b - Oil grooves on thrust bearing
b 48457

95 2-4-C with PTFE Smooth side of center main thrust bearing 92-802859A 1
6. Verify the locating dowel pins are on the cylinder block.
7. Install the balance shaft chain onto the gear at the flywheel end of the crankshaft and carefully lower the crankshaft onto
the cylinder block main bearings.
a - Balance shaft chain

b - Main bearings with oil groove
48469
90-8M0060785 DECEMBER 2011 Page 4A-57

8. Install a piece of plastigauge parallel to the crankshaft on the main bearing journals.
48495
9. Install the bedplate onto the cylinder block.

IMPORTANT: Do not allow the crankshaft to rotate when checking the bearing clearance with plastigauge.
10. Install the 10 main bearing M10 x 95 flange head screws.
11. Tighten the screws in three steps to the specified torque in the sequence shown.
6 2 4
10 8
9 7
5 1 3
48454

First 15 132.7
M10 x 95 flange head screw (10) Second 40 29.5
12. Loosen the screws in the reverse order.
Page 4A-58 90-8M0060785 DECEMBER 2011

13. Remove the bedplate and measure the plastigauge width. If the compressed plastigauge measurement is not within the
listed specification, check the crankshaft code and measurement, cylinder block main bearing code, and the bearing code
selection.
48498
Main Bearing
Oil clearance 0.052–0.086 mm (0.002–0.0033 in.)
14. If the measurement is within specification, remove the plastigauge material from the bearing and crankshaft surface.
15. Remove the crankshaft from the cylinder block. Lubricate the main bearings and thrust bearing with engine assembly
lubricant. Engine assembly lubricate can be purchased locally.
16. Apply a continuous 2 mm bead of Three Bond 1217F to the bedplate as shown in the following illustration.
48453
Sealant bead

135 Three Bond 1217F Bedplate cylinder block seal area 92-858005K02
17. Install the bedplate and the 10 main bearing M10 x 95 flange head screws.
90-8M0060785 DECEMBER 2011 Page 4A-59

18. Tighten the screws in three steps to the specified torque in the sequence shown.
6 2 4
10 8
9 7
5 1 3
48454

First 15 132.7
M10 x 95 flange head screw (10) Second 40 29.5
19. Install the twelve perimeter bedplate M8 x 50 flange head screw.

20. Tighten the screws to the specified torque in the sequence shown.
6 2 4 8
10
12
9 5 1 3 11
7
48455

M8 x 50 flange head screw (12) 35 25.8
Piston/Connecting Rod Assembly

1. Install the connecting rod into the piston with the connecting rod part number facing down and the dot on the piston dome
facing up.
2. Lubricate the piston pin with Lubriplate SPO 255.
3. Assemble the piston, connecting rod, piston pin, and secure with new piston pin retaining clips.
Page 4A-60 90-8M0060785 DECEMBER 2011

IMPORTANT: The opening of the piston pin retaining clip should face towards the crown of the piston.
d a- Connecting rod (part number facing down)

b- Piston (dot on the piston dome facing up)
c
c- Piston pin
d- Piston pin retaining clip (2)
b
47994

136 Lubriplate SPO 255 Piston pin Obtain Locally
Piston Ring Installation

IMPORTANT: Always install new rings when rebuilding engine. Use caution when installing piston rings to avoid scratching
piston.
1. Apply Synthetic Blend 4‑Stroke Outboard Oil 25W‑40 to the piston ring grooves.
NOTE: For reference demarcation, the dot on the piston is at the 12 o'clock position and points towards the flywheel.

139 Piston ring grooves 92-858052K01
Outboard Oil 25W-40
2. Install the oil ring expander onto the lower ring groove of the piston. Verify the ring gap is at the 2 o'clock position.
IMPORTANT: The oil ring spacer cannot be rotated after the bottom and top oil control rings are installed.
3. Install the bottom oil control ring. Verify the ring gap is at the 4 o'clock position.
4. Install the top oil control ring. The top oil ring uses a locating pin on the piston.
5. Install the second compression ring with the dot side up. Verify the ring gap is at the 3 o'clock position.
90-8M0060785 DECEMBER 2011 Page 4A-61

6. Install the top compression ring with the dot side up. Verify the ring gap is at the 9 o'clock position.
a
b
e d
c
c
b
a
e
d
h f
i j
g
47997
a- Top oil control ring

b- Oil ring expander
c- Bottom oil control ring
d- Top compression ring
e- Second compression ring
f- Oil ring expander (ring gap is at the 2 o'clock position)
g- Bottom oil control ring gap (ring gap is at the 4 o'clock position)
h- Top oil control ring gap (locating pin)
i- Top compression ring gap (ring gap is at the 9 o'clock position)
j- Second compression ring gap (ring gap is at the 3 o'clock position)
Connecting Rod Bearing Grade Selection

Connecting Rod
Bearing oil clearance 0.052–0.082 mm (0.002–0.0032 in.)
Page 4A-62 90-8M0060785 DECEMBER 2011

1. Verify the crankshaft journal code on cylinder number one top counterweight.

48421
2. Verify the journal code on the connecting rod cap.
a - Stamped connecting rod crankshaft journal code "I"

b - Stamped connecting rod crankshaft journal code "0"
a b
0
47985
Connecting Rod Journal Code

56.508–56.514 mm
Journal code "I"
(2.2247–2.2249 in.)
56.514–56.520 mm
Journal code "0"
(2.2249–2.2251 in.)
3. Refer to the following bearing selection chart to select the correct crankshaft connecting rod bearings.
IMPORTANT: After selecting the correct bearing, install the bearing halves in the connecting rod and the matching
connecting rod cap to avoid mixing bearing sizes.
Connecting Rod Journal Code Crankshaft Journal Code Bearing Color Selection
I C Blue
I D White
0 C White
0 D Orange
4. Ensure the connecting rod bearing area is clear of debris and contamination.
5. Install the locating tab of the upper half of the bearing into the slot on the connecting rod, and the locating tab of the lower
half of the bearing into the slot on the connecting rod cap. Carefully push the bearing onto the connecting rod and
connecting rod cap.
a - Connecting rod
b - Connecting rod locating tab
b
a
4389
90-8M0060785 DECEMBER 2011 Page 4A-63

Piston Connecting Rod Assembly Installation

1. Lubricate the piston and rings with Synthetic Blend 4‑Stroke Outboard Oil 25W‑40.

139 Piston and rings 92-858052K01
Outboard Oil 25W-40
2. Verify the location of the ring gaps.
Ring Gap Location

Top ring 9 o'clock position
Second ring 3 o'clock position
Top oil control ring Locating pin
Oil ring expander 2 o'clock position
Bottom oil control ring 4 o'clock position
3. Install the ring compressor from the connecting rod end. Ensure the taper side of the ring compressor engages the piston
first. The ring compressor should be purchased locally.
a - Taper side of the ring compressor
48470
a
4. Carefully push the ring compressor onto the piston until the piston is even with the ring compressor.
NOTE: Do not force the ring compressor onto the piston. If the ring compressor installation is difficult, the top oil control
ring end gap may not be aligned with the locating pin on the piston.
48472
5. Lubricate the cylinder bore with a generous amount of Synthetic Blend 4‑Stroke Outboard Oil 25W‑40.

139 Cylinder bore 92-858052K01
Outboard Oil 25W-40
6. Install the piston into the cylinder bore with the piston demarcation towards the flywheel side of the engine.
7. Ensure the ring compressor circumference rests completely on the cylinder block deck.
8. Secure the ring compressor to the cylinder block deck and push the piston into the cylinder bore.
Page 4A-64 90-8M0060785 DECEMBER 2011

NOTE: Do not force the piston assembly into the cylinder bore by striking it with a wood handle or other tool handle.
a a - Piston demarcation towards the flywheel

b - Ring compressor circumference completely on the cylinder
block deck
b
48473
9. Verify the connecting rod is properly aligned with the crankshaft and push the connecting rod onto the crankshaft.
10. Install a piece of plastigauge parallel to the crankshaft on the connecting rod crankshaft journal.
48506
11. Lubricate the rod cap screw threads and under the screw head with Lubriplate SPO 255.

12. Install the rod cap and screws. Verify the rod cap alignment and tighten the screws in three stages to the specified torque.
IMPORTANT: Do not allow the crankshaft to rotate when checking the bearing clearance with plastigauge.
a - Rod cop screws
48508

First 10 88.5
90-8M0060785 DECEMBER 2011 Page 4A-65

13. Remove the rod cap and measure the plastigauge width. If the compressed plastigauge measurement is not within the
listed specification, check the crankshaft measurement, connecting rod measurement, and the bearing grade selection.
48510
Connecting Rod
Bearing oil clearance 0.052–0.082 mm (0.002–0.0032 in.)
14. If the clearance is within the listed specifications, carefully remove the plastigauge material from the bearing and crankshaft
surface.
15. Push the connecting rod away from the crankshaft and apply engine assembly lubricant to the bearing and journal. Engine
assembly lubricant can be purchased locally.
16. Pull the connecting rod onto the crankshaft journal.
17. Lubricate the rod cap screw threads and under the screw head with Lubriplate SPO 255.

18. Install the rod cap and screws. Verify the rod cap alignment and tighten the screws in three stages to the specified torque.

First 10 88.5
19. Install the remaining connecting rod assemblies, checking the bearing clearance before applying the lubrication for the final
assembly process.
Balance Shaft Assembly Installation

1. Install the flywheel key and flywheel. Secure the flywheel with the flywheel screw and washer. Do not torque the screw.
2. Secure the balance shaft chain so not to interfere with the rotation of the crankshaft.
Page 4A-66 90-8M0060785 DECEMBER 2011

3. Align the flywheel timing mark with the timing mark on the cylinder block.
a - Flywheel timing mark

b - Cylinder block timing mark
a
48477
4. Align the balance shaft assembly gears timing demarcations.
48475
5. Lift the balance shaft chain and verify the chain is fully engaged with the crankshaft gear.
6. Install the balance shaft assembly and engage the chain onto the balance shaft assembly gear.
7. Check the alignment of the balance shaft demarcations and flywheel timing marks. If they are not aligned, correct the
condition and push the balance shaft assembly housing onto the bedplate.
8. Rotate the flywheel two revolutions in a right‑hand rotation and align the flywheel timing mark with the cylinder block timing
mark. Do not counter rotate the flywheel to align the timing marks while performing this process.
9. Lightly push on the slack side of the balance shaft chain and check the alignment of the balance shaft demarcations. If they
are not aligned, correct the misalignment.
a - Slack side of the balance shaft chain

b b - Balance shaft demarcations
48478
10. Remove the flywheel.
11. Install the screws to secure the balance shaft assembly to the bedplate. Do not tighten the screws.
90-8M0060785 DECEMBER 2011 Page 4A-67

IMPORTANT: The torque sequence of the balance shaft assembly must be followed exactly. Failure to follow the torque
sequence may cause damage that cannot be repaired.
12. Ensure all of the balance shaft assembly screws are loose.
13. Tighten the nine screws to the specified torque in the sequence shown.
9
7
5
1 3
4
6
8
48479

Balance shaft assembly screws 10 88.5
14. Tighten the specified screws 90° in the sequence shown.
1 3
48480
Page 4A-68 90-8M0060785 DECEMBER 2011

48481
2 4
1
3
48482
17. Assemble the chain tensioner.
a c d
b e f
47742
a- Tensioner face
b- Tensioner
c- Vent disc
d- Spring
e- Check valve
f- Housing
18. Install the fixed chain guide onto the tensioner bracket and secure with two M6 x 20 screws. Tighten the screws to the
specified torque.
19. Install the chain tensioner housing and secure with two M6 x 30 screws. Tighten the screws to the specified torque.
90-8M0060785 DECEMBER 2011 Page 4A-69

20. Lubricate the tensioner assembly and tensioner spring with Lubriplate SPO 255.
21. Insert the spring and tensioner assembly into the housing.
a- Fixed chain guide screws (M6 x 20)

b- Tensioner housing screws (M6 x 30)
b c- Tensioner spring
a d- Tensioner assembly
c
d
48491

Fixed chain guide screws (M6 x 20) 10 88.5
Tensioner housing screws (M6 x 30) 10 88.5

136 Lubriplate SPO 255 Balance shaft tensioner assembly and tensioner spring Obtain Locally
22. Push the chain tensioner in and insert a ridged piece of wire to retain the chain tensioner. A large paper clip works well as
a ridged piece of wire.
IMPORTANT: The wire should be long enough so not to be overlooked during the engine assembly process.
48492
23. Install the chain tensioner assembly and secure with two M8 x 25 screws. Tighten the screws to the specified torque.
Page 4A-70 90-8M0060785 DECEMBER 2011

24. Verify the chain is aligned with the guide and tensioner. Remove the wire from the chain tensioner.
a - Tensioner assembly screws

b b - Wire (remove)
a
48493

Tensioner assembly screws (M8 x 25) 14 124
Bedplate Cover Installation

1. Install a new gasket seal onto the bedplate cover.
2. Verify the contact surface of the bedplate is clear of debris and contamination.
3. Install the bedplate cover onto the bedplate.
4. Secure the cover with ten M6 x 25 screws.
5. Tighten the screws to the specified torque in the sequence shown.
6 2 4 9
10
5 1 3 8

Bedplate cover screws 10 88.5
Cylinder Head Installation

IMPORTANT: It is expected the valve clearance will change to a value that minimizes the amount of additional adjustment
after the cylinder head is installed and torqued to specification.
1. Install the flywheel and secure with the washer and bolt. Do not tighten the bolt.
2. Align the timing mark with the aft starter mounting boss on the cylinder block.
90-8M0060785 DECEMBER 2011 Page 4A-71

IMPORTANT: Rotating the crankshaft to align the flywheel timing mark with the aft starter mounting boss, allows for
sufficient valve clearance to rotate the camshaft when the cylinder head is secured to the cylinder block.
a - Starter mounting boss

b - Timing mark
b
a
48539
3. Verify the dowel pins are installed on the cylinder block.
4. Install the cylinder head gasket.
5. Install the cylinder head and secure with ten M10 x 95 flange head screws.
6. Tighten the screws in three stages to the specified torque in the sequence shown.
7 3 1 5
9
8 4 2 6 10
48540

First 15 132.7
M10 x 95 flange head screws (10) Second 30 22.1
Final Turn addtional 90°
Page 4A-72 90-8M0060785 DECEMBER 2011

7. Install three M6 x 40 screws and tighten to the specified torque in the sequence shown.
3 1 2
48541

M6 x 40 screws 10 88.5
8. Install the timing chain tensioner guide and fixed chain guide. Secure with guides to the cylinder block with M8 x 37
shoulder screw. Apply Synthetic Blend 4‑Stroke Outboard Oil 25W‑40 to the flange head of the shoulder screw. Apply
Loctite 242 Threadlocker to the screw threads. Tighten the screws to the specified torque.
9. Install the crankshaft O‑ring and lubricate with 2‑4‑C with PTFE.
a - Tensioner guide screw

b - O‑ring
b c - Fixed guide screw
48549

Tensioner guide screws 24 17.7

139 Flange head of shoulder screw 92-858052K01
Outboard Oil 25W-40
66 Loctite 242 Threadlocker Tensioner guide screw threads 92-809821
95 2-4-C with PTFE Crankshaft O-ring 92-802859A 1
90-8M0060785 DECEMBER 2011 Page 4A-73

10. Verify the camshaft is positioned so the pin on the camshaft is at 9 o'clock.
48542
11. Rotate the flywheel clockwise and align the flywheel timing mark to the TDC mark on the cylinder block.
a - TDC mark on the cylinder block

b - Flywheel timing mark
48543
12. Locate the timing chain links that are marked with yellow paint. The link with the line is for the crankshaft timing mark and
the link that is yellow is for the camshaft timing mark.
IMPORTANT: If the yellow paint on the timing chain links cannot be identified, a new timing chain should be installed.
a b a - Camshaft link timing mark

b - Crankshaft link timing mark
48545
Page 4A-74 90-8M0060785 DECEMBER 2011

13. Install the timing chain link with the yellow line onto the crankshaft. Verify the link with the line is aligned with the timing
mark on the crankshaft.
a a - Yellow line on timing chain link

b - Crankshaft timing chain alignment mark
48550
14. Install the camshaft gear onto the timing chain, aligning the yellow link with the triangle on the gear and install the camshaft
gear onto the camshaft.
a - Yellow link
b c b - Camshaft gear timing mark
c - Camshaft pin
48551
15. Lubricate the special left‑hand thread camshaft gear screw threads and flange head with Synthetic Blend 4‑Stroke
Outboard Oil 25W‑40 and retain the camshaft gear with the camshaft gear screw.

139 Camshaft gear screw threads and flange head 92-858052K01
Outboard Oil 25W-40
16. Secure the camshaft and tighten the screw in two stages to the specified torque.
90-8M0060785 DECEMBER 2011 Page 4A-75

17. After the first torque is completed, mark the camshaft gear at the first line on the camshaft gear screw. Rotate the screw to
align with the 20° mark on the camshaft gear.
a - Camshaft gear first

b torque location 45 Nm
(33.2 lb‑ft)
c b - Camshaft gear mark
c - 20° mark on the
camshaft gear screw
a
48552

First 45 32.2
Camshaft gear screw (left‑hand thread)
18. Apply Lubriplate SPO 255 to the timing chain tensioner assembly and insert into the cylinder head.
48553

136 Lubriplate SPO 255 Timing chain tensioner assembly Obtain Locally
19. Install an O‑ring onto the timing chain tensioner cover and secure with a bracket and two M6 x 25 flange head screws.
Tighten the screws to the specified torque.
a - Timing chain tensioner cover

a b - Bracket
c - Screws (2)
c
48554
Page 4A-76 90-8M0060785 DECEMBER 2011


Screws (M6 x 25) (2) 10 88.5
20. Check the lash on all the valves and correct if necessary. Refer to Section 4B ‑ Adjusting Valve Clearance.
IMPORTANT: The clearance specifications apply when the ball stud locknut is tightened to the specified torque.
IMPORTANT: When measuring clearance with a feeler gauge blade, you must change sizes until you feel a firm drag
when pushing and pulling on the gauge. Verify your results by trying the next size larger blade. It must be much more
difficult or nearly impossible to enter the gap. Then try the next size smaller blade. It must have little or no drag. If your
results are different, your technique is incorrect. Common mistakes are failing to hold the blade perpendicular to the gap or
twisting and flexing the blade.
Camshaft to Roller Clearance Specifications

Intake valve 0.0762 mm (0.003 in.)
Exhaust valve 0.254 mm (0.010 in.)

Ball stud locknut 20 177
21. Install a new cam cover seal and install the cam cover.
22. Secure the cover with 12 M6 x 25 screws. Tighten the screws to the specified torque in the sequence shown.
7
8
5
4
1
2
3
6
9
10
11 12 48612

M6 x 25 screws (12) 10 88.5
Crankshaft Seal Installation

1. Clean the crankshaft seal bore with a mild solvent and allow to dry.
90-8M0060785 DECEMBER 2011 Page 4A-77

2. Insert the spacer into the seal bore.
48586
3. Lubricate the crankshaft seal lip with Engine Coupler Spline Grease and install the seal onto the crankshaft.
48587

91 Crankshaft seal lip 92-802869A 1
Grease
4. Use an appropriate driver tool to install the crankshaft seal.
5. Install the flywheel washer and screw. Tighten the screw to the specified torque.
a b a- Screw
b- Washer
c c- Driver
d- Seal
48589

Screw 27 20
Page 4A-78 90-8M0060785 DECEMBER 2011

6. Remove the tool and install the retaining ring.
48590
Seal Installation for a Worn Crankshaft Seal Area

When a seal groove has worn into the crankshaft, press the seal into the cylinder block and then install the spacer. Retain the
spacer and seal with the retaining ring.
a a - Retaining ring
b - Spacer
b c - Seal
48591
Oil Pump Installation

1. Verify the crankshaft is at TDC.
a - TDC mark on the cylinder block

b - Flywheel timing mark
48543
90-8M0060785 DECEMBER 2011 Page 4A-79

2. Pour approximately 30 cc (1.0 oz) of engine oil into the oil pump and rotate the oil pump drive gerotor to distribute the oil.
a - Oil pump drive gerotor

b - Pour approximately 30 cc (1.0 oz) of engine oil into the
oil pump
b
a
48557
3. Align oil pump drive gerotor as shown in the following graphic.
48558
4. Lubricate the oil pump seal lip and the oil pump gerotor drive flats with Engine Coupler Spline Grease.

91 Oil pump seal lip and oil pump gerotor drive flats 92-802869A 1
Grease
5. Install the oil pump assembly onto the cylinder block and secure with four M6 x 45 screws.
6. Verify the oil pump is correctly seated on the cylinder block and tighten the screws to the specified torque in the sequence
shown.
2
4
48559

M6 x 45 screws (4) 10 88.5
Page 4A-80 90-8M0060785 DECEMBER 2011

Installing Powerhead Components

Component Installation
1. Replace the O‑ring on the block water temperature sensor.
13384
2. Apply Loctite 567 PST Pipe Sealant to the threads of the block water temperature sensor and install onto the cylinder
block. Tighten the block water temperature sensor to the specified torque.
3. Apply Loctite 567 PST Pipe Sealant to the threads of the water pump indicator hose plastic fitting and install onto the
cylinder head. Tighten the fitting securely.
4. Install the crankshaft position sensor and secure with two M5 x 13 screws. Tighten the screws to the specified torque.
a - Water pump indicator hose plastic fitting

b - Block water temperature sensor
c - Crankshaft position sensor
b c
a
48267

Loctite 567 PST Pipe Water pump indicator hose plastic fitting threads, block
9 92-809822
Sealant water temperature sensor threads

Block water temperature sensor 15 132.7
Crankshaft position sensor screws 5 45
5. Install a new O‑ring onto the thermostat housing.
6. Secure the thermostat housing to the cylinder block with two M6 x 25 screws. Tighten the screws to the specified torque.
7. Install the water pump indicator hose onto the plastic fitting and secure the hose with a cable tie.
a - Plastic fitting
b - M6 x 25 screws
c - Water pump indicator hose
b
48934

M6 x 25 screws 8 70.8
90-8M0060785 DECEMBER 2011 Page 4A-81

8. Apply Loctite 567 PST Pipe Sealant to the threads of the oil pressure sensor and install onto the cylinder block. Tighten the
oil pressure sensor to the specified torque.
9. Secure the thermostat dump hose to the cylinder block with the plastic retainers.
a - Oil pressure sensor

a b - Plastic retainers securing the hose
48266

9 Oil pressure sensor threads 92-809822
Sealant

Oil pressure sensor 15 132.7
10. Verify the intake manifold seals are installed.
48271
11. Install the intake manifold onto the cylinder head and secure with 11 M6 x 40 flange head screws. Tighten the screws to
Page 4A-82 90-8M0060785 DECEMBER 2011

12. Install the crankcase ventilation hose adapter onto the throttle body.
a - Crankcase ventilation hose adapter

b - Screws securing the intake manifold
a
b
b
48263

M6 x 40 flange head screws (11) 10 88.5
13. Secure the manifold reference hose, thermostat dump hose, and water pump indicator hose with the plastic retainers.
a - Manifold reference hose plastic retainer

b - Water pump indicator hose plastic retainer
c - Thermostat dump hose plastic retainer
a
c
48261
14. Secure the shift bracket to the cylinder block with three M6 x 25 screws. Tighten the screws to the specified torque.
15. Install the drip tray and secure with two M6 x 20 shoulder screws. Tighten the screws to the specified torque.
90-8M0060785 DECEMBER 2011 Page 4A-83

16. Lubricate the seal on the oil filter and install onto the cylinder block. Tighten the oil filter to the specified torque.
a - Oil filter
a
b - Oil filter drip tray shoulder screws
c - Screws securing the shift bracket
c 48260

Shift bracket screws (M6 x 25) (3) 10 88.5
Drip tray shoulder screws (M6 x 20) (2) 10 88.5
Oil filter 20 177
17. Install the starter and secure with two M8 x 80 screws in the upper mounts and one M8 x 45 screw in the lower mount.
Tighten the screws to the specified torque.
18. Secure the starter ground cable to the cylinder block with a M6 x 13 screw. Tighten the screw to the specified torque. Apply
Liquid Neoprene to the ground screw to protect against corrosion.
a - Screw securing the starter ground

b - Screws securing the starter
48258
a

Starter mounting screws (M8 x 80 [2], M8 x 45 [1]) 21 185.8
Starter ground screw (M6 x 13) 10 88.5

25 Liquid Neoprene Ground screw 92- 25711 3
19. Apply Loctite 567 PST Pipe Sealant to the threads of the plastic elbow and install onto the cylinder block. Tighten the fitting
securely.
Page 4A-84 90-8M0060785 DECEMBER 2011

20. Secure the powerhead fresh water flush hose to the cylinder block with a cable tie. Do not overtighten the cable tie.
a - Cable tie
b - Flush hose threaded plastic elbow
b
48256

9 Plastic elbow threads 92-809822
Sealant
21. Secure each ignition coil with two M6 x 30 screws. Tighten the screws to the specified torque.
a - Cylinder 1 and 4 ignition coil

a b - Cylinder 2 and 3 ignition coil
48620

M6 x 30 screws 10 88.5
22. Ensure the crankshaft and the flywheel taper is clean of contamination and debris.
23. Install the flywheel key.
24. Install the flywheel and secure with a M20 x 68 screw and washer.
25. Secure the flywheel with the flywheel holding tool and tighten the screw to the specified torque in two stages.

First 100 73.7
Flywheel screw
Final 200 147.5
26. Install the alternator onto the cylinder block. Secure the alternator with a M10 x 60 flange head screw. Do not tighten the
screw.
90-8M0060785 DECEMBER 2011 Page 4A-85

a - Alternator belt letters are legible

a
b
48621
28. Push the alternator towards the cylinder head and install a M10 x 60 flange head screw. Tighten the M10 x 60 screws to
48624

M10 x 60 screw (2) 50 36.8
Wire Harness Installation

1. Install the electrical cover and secure with three M6 x 25 flange head screws and washers. Tighten the screws to the
specified torque.
2. Secure the 14 pin engine harness connector with the retainer.
3. Secure the engine harness to the cylinder block with a cable tie.
Page 4A-86 90-8M0060785 DECEMBER 2011

4. Route the engine harness behind the alternator.
a- M6 x 25 flange head screws (3)

b- 14 pin engine harness connector retainer
c- Cable tie
d- Engine harness behind alternator
d
a
c
48626

Screws securing electrical cover (M6 x 25) 10 88.5
5. Connect the engine harness connectors to the upper and lower ignition coils.
6. Secure the lower ignition coil engine wire harness to the cylinder block with a cable tie.
a - Ignition coil harness connection

b - Cable tie
48630
7. Secure the three engine harness grounds to the cylinder block with a M6 x 15 screw. Tighten the screw to the specified
torque.
8. Apply Liquid Neoprene to the ground connection to prevent corrosion.
9. Connect the engine harness alternator sense connector to the alternator.
10. Install the fusible link to the alternator and secure with the nut. Tighten the nut to the specified torque. Apply Liquid
Neoprene to the connection and allow to dry.
90-8M0060785 DECEMBER 2011 Page 4A-87

11. Cover the connection with the insulator boot.
b a - Three engine harness grounds

b - Insulator boot
c - Alternator sense connector
48631

M6 x 15 screw 10 88.5

Ground on cylinder block, fusible link connection on
25 Liquid Neoprene 92- 25711 3
alternator
12. Route the engine harness between the ECU mounting locations on the bedplate cover and secure the ECU to the bedplate
cover with three M6 x 25 screws. Tighten the screws to the specified torque.
a - Engine harness between the ECU mounting

b - Screws securing ECU
a
48634

Screws securing ECU (M6 x 25) 10 88.5
13. Connect the engine harness yellow with red tracer starter exciter wire to the starter solenoid terminal and secure with a
lockwasher and nut. Tighten the nut to the specified torque. Apply Liquid Neoprene to the connection to protect against
corrosion.
14. Connect the power lead from the hot stud to the starter terminal and secure with the nut. Do not tighten the nut. The battery
cable will be installed after the powerhead is secured to the driveshaft housing.
Page 4A-88 90-8M0060785 DECEMBER 2011

15. Secure the engine harness connectors to the bedplate cover.
a- Nut securing yellow with red tracer starter exciter wire

b- Power lead from the hot stud
c- Diagnostic connector
d- Boat sensor harness connector
a
b
48636

Nut securing yellow with red tracer starter exciter wire 2.5 22

25 Liquid Neoprene Starter solenoid exciter terminal 92- 25711 3
16. Connect the engine harness connector onto the shift position indicator and secure with cable ties.
a - Shift position indicator harness connector

b - Cable ties (2)
b
a
b
48637
17. Route the engine harness under the cylinder block water dump hose and behind the throttle body.
18. Route the engine harness under the FSM coolant hose and the crankcase ventilation hose so it is by the fuel rail.
90-8M0060785 DECEMBER 2011 Page 4A-89

19. Connect the engine harness connectors to the crankshaft position sensor and the cylinder block temperature sensor.
Secure the crankshaft position sensor and the cylinder block temperature sensor to the engine harness with a cable tie.
b a - Cable tie
b - Engine harness behind throttle body
c - Engine harness by the fuel rail
c
a
48638
20. Connect the engine harness connector to the manifold air temperature sensor and secure the harness to the connector
with a cable tie.
21. Connect the engine harness connectors to the fuel injectors.
22. Twist the engine harness so the fuel injector connector harness lead points aft and secure the engine harness to the intake
manifold with five cable ties.
a - Cable tie (5)

b - Fuel injector connector harness lead
points aft
c - Cable tie (manifold air temperature
sensor)
a
b
48242
IMPORTANT: The powerhead must be installed onto the driveshaft housing before the exhaust manifold can be installed.
Powerhead Installation onto the Midsection

1. Install the flywheel puller/lifting ring and secure with the screws. Tighten the screws to the specified torque.

Flywheel puller/lifting ring screws 27 20
2. Suspend the powerhead to access the oil pump.
Page 4A-90 90-8M0060785 DECEMBER 2011

3. Install a 39.6 mm metal hose clamp onto the oil pickup tube. Install the oil pickup tube onto the oil pump. Use the hose
clamp tool to secure the pickup tube to the oil pump. The crimped side of the metal hose clamp must face towards the
crankshaft.
a - 39.6 mm metal hose clamp
48074

4. Install the powerhead gasket onto the adapter plate.
5. Verify the exhaust tube screw is loose.
6. Carefully lower the powerhead onto the midsection.
7. Install four M10 x 60 screws on the port side of the midsection. Do not tighten the screws.
a a - Exhaust tube screw

b - M10 x 60 screws (4)
48655
8. Install five M10 x 60 screws on the starboard side of the midsection. Do not tighten the screws.
48070
90-8M0060785 DECEMBER 2011 Page 4A-91

9. Install three M8 x 40 screws at the back of the midsection. Do not tighten the screws.
48057
10. Lubricate the two exhaust manifold joints with a mild liquid detergent.
11. Lubricate the O‑rings on the exhaust tube with a mild liquid detergent.
12. Install the exhaust manifold gasket onto the cylinder head locating pins.
a - O‑rings on the exhaust tube

b - Exhaust manifold gasket
c - Locating pins
b
c
48664
Page 4A-92 90-8M0060785 DECEMBER 2011

13. Install the exhaust manifold onto the exhaust tube and push down on the exhaust manifold.
48665
14. Rotate the exhaust manifold onto the cylinder head, aligning the pins on the head with the holes in the exhaust manifold.
15. Secure the exhaust manifold with nine M8 x 60 flange head screws. Tighten the screws in the sequence shown to the
specified torque in two stages.
16. Install the spark plugs and tighten to the specified torque.
17. Install the spark plug wires to the spark plug and coils.
9
8 a - Ignition coil cylinder 1 and 4
b - Ignition coil cylinder 2 and 3
6
5
a 2
1
3
4
b 7
48666

First 15 132.7
Exhaust manifold screws (M8 x 60) (9)
Final 28 20.6
Spark plugs 27 20
90-8M0060785 DECEMBER 2011 Page 4A-93

18. Tighten the exhaust tube M6 x 25 screw to the specified torque.
48667

Exhaust tube screw (M6 x 25) 10 88.5
19. Tighten the powerhead mounting screws to the specified torque in the sequence shown.
6 8
7
5
3
1
2
4
12
11
10 9
48669

Powerhead mounting screws 1–8 and 12 (M10 x 60) 60 44
Powerhead mounting screws 9–11 (M8 x 40) 27 20
20. Insert the positive battery cable through the insulator boot and secure to the starter solenoid with the nut. Tighten the nut to
the specified torque. Apply Liquid Neoprene to the terminal to protect against corrosion and allow to dry. Protect the
terminal with the insulator boot.
21. Secure the negative battery cable to the starter with a M8 x 20 flange head screw. Tighten the screw to the specified
torque. Apply Liquid Neoprene to protect against corrosion.
Page 4A-94 90-8M0060785 DECEMBER 2011

22. Secure the battery cables and engine harness to the bedplate cover with two cable ties.
b a - M8 x 20 flange head screw

b - Insulator boot
a c - Cable ties
48670

Nut securing positive battery cable to starter 9 79.6
M8 x 20 flange head screw 17 150.4

25 Liquid Neoprene Negative battery cable connection on starter 92- 25711 3
23. Install the shift link onto the shift shaft and secure with a washer and nut. Tighten the nut to the specified torque.
a - Nut and washer

a b - Shift link
48059

Nut 6 53.1
24. Install a new O‑ring onto the strainer.

25. Install the strainer onto the exhaust tube water jacket and secure with two M6 x 25 screws. Tighten the screws to the
specified torque.
90-8M0060785 DECEMBER 2011 Page 4A-95

26. Install the hoses to the strainer fittings and secure with cable ties.
a - Cable ties securing the hoses

b - Screws securing the strainer
b
a
48068

M6 x 25 screws 10 88.5
27. Secure the speedometer hose to the shift bracket with the retainer.
28. Install the fuel filter and connect the fuel supply hose to the fuel filter outlet port.
29. Connect the water pump indicator hose to the fitting and secure with a cable tie.
d a- Cable tie
b- Water pump indicator fitting
c- Fuel supply hose to the fuel filter outlet port
d- Retainer on the shift bracket
b
c
48064
30. Install new O‑rings onto the water dump hose fitting and insert the fitting onto the adapter plate. Secure the fitting with a M6
x 25 screw. Tighten the screw to the specified torque.
31. Install the manifold pressure reference line onto the fuel supply module.
32. Install a 15.7 mm metal hose clamp onto the high‑pressure fuel line and install onto the fuel rail. Use the clamp tool to
secure the high‑pressure fuel hose to the fuel rail fitting.
Page 4A-96 90-8M0060785 DECEMBER 2011

33. Connect the engine harness connector to the fuel pump connector and secure to the MAT sensor harness with a cable tie.

a b line
c - Cable tie securing the fuel pump connector
e - Screw securing the water dump hose fitting
e c
d
48055

M6 x 25 screw 10 88.5

34. Install the muffler onto the hose and secure with a cable tie.
35. Secure the muffler to the adapter plate with a M6 x 16 screw. Tighten the screw to the specified torque.
b a - M6 x 16 screw
b - Cable tie
a
48054

M6 x 16 screw 10 88.5
Engine Break‑in Procedure

IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine
and can cause engine damage. Always follow break‑in procedures.
1. 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.
2. For the next eight hours of operation, avoid continuous operation at full throttle for more than five minutes at a time.
90-8M0060785 DECEMBER 2011 Page 4A-97

Notes:
Page 4A-98 90-8M0060785 DECEMBER 2011

Cylinder Head
Powerhead
Section 4B - Cylinder Head
Table of Contents
Cylinder Head Specifications............................................. 4B-2 Valve Springs............................................................4B-12
Cylinder Head.................................................................... 4B-4 Cylinder Head........................................................... 4B-13
Cylinder Head and Valve Train Components.....................4B-6 Valve Guides............................................................ 4B-14
Cylinder Head Service Recommendations........................ 4B-8 Valve Seat Reconditioning........................................4B-15
Cylinder Head Disassembly...............................................4B-8 Cylinder Head Assembly..................................................4B-16
Camshaft Removal..................................................... 4B-8
Cylinder Head Galley Plug Removal........................ 4B-10
Cylinder Head Galley Plug Installation..................... 4B-16
Valve Installation.......................................................4B-17 4
Cleaning, Inspection, and Repair.....................................4B-10
Camshaft.................................................................. 4B-10
Camshaft Installation................................................ 4B-18
Adjusting Valve Clearance........................................4B-20 B
Valve Specifications..................................................4B-11
90-8M0060785 DECEMBER 2011 Page 4B-1

Cylinder Head

Maximum warp 0.1 mm (0.0039 in.)
Deck
Minimum datum height (combustion chamber) 7 mm (0.275 in.)
Number of valves 8
Number of valves per cylinder 2
29.000–29.021 mm
Camshaft bearing inside diameter (cylinder head)
(1.1417–1.1425 in.)
19.975 ± 0.025 mm
Cylinder head camshaft center bearing thrust face
(0.7864 ± 0.0009 in.)
28.97 ± 0.01 mm
Camshaft bearing journal
(1.1405 ± 0.0004 in.)
Intake 48.05 mm (1.892 in.)
Camshaft lobe height
Camshaft to roller clearance Intake 0.0762 mm (0.003 in.)

(lash) Exhaust 0.254 mm (0.010 in.)
Intake 30°, 44°, 60°
Valve seat angles
Exhaust 25°, 44°, 65°
Intake 1.02 ± 0.1 mm (0.04 ± 0.0039 in.)
Valve seat width (44°)
Exhaust 1.8 ± 0.1 mm (0.07 ± 0.0039 in.)
57.08 ± 0.25 mm
Uncompressed
(2.247 ± 0.0098 in.)
350 ± 25 N (78.68 ± 5.62 lbf)
Valve spring height Compressed to 50.24 mm (1.977 in.)
spring pressure
1039 ± 45 N (233.57 ± 10.11 lbf)
Compressed to 36.78 mm (1.448 in.)
spring pressure
Intake 50.8 ± 0.13 mm (2.0 ± 0.005 in.)
Valve outside diameter
Exhaust 39.4 ± 0.13 mm (1.55 ± 0.005 in.)
Valve face angle Intake and exhaust 45°
0.38 ± 0.2 mm
Intake
(0.0149 ± 0.007 in.)
Valve margin width
1.46 ± 0.35 mm
Exhaust
(0.0574 ± 0.0137 in.)
7.966 ± 0.01 mm
Valve stem diameter Intake and exhaust
(0.313 ± 0.0003 in.)
Valve stem runout (service limit
Intake and exhaust 0.038 mm (0.0015 in.)
measured at valve face)
125.14 ± 0.30 mm
Intake
(4.9267 ± 0.0118 in.)
Valve height
126.29 ± 0.30 mm
Exhaust
(4.9720 ± 0.0118 in.)
8.001–8.021 mm
Valve guide bore inside diameter Intake and exhaust
(0.3149–0.3157 in.)
Valve stem to valve guide 0.025–0.065 mm
Intake and exhaust
clearance (0.001–0.0025 in.)
24.9 ± 0.25 mm
Valve guide height Intake and exhaust
(0.980 ± 0.0098 in.)
Page 4B-2 90-8M0060785 DECEMBER 2011

Cylinder Head

95 2-4-C with PTFE Installing valve spring retainer locks 92-802859A 1
Galley plug threads
Synthetic Blend 4-Stroke Valve guide seal
139 92-858052K01
Outboard Oil 25W-40 Ball stud assembly threads
Rocker arm roller bearing
Special Tools
Valve Spring Compressor 91‑809494A 1
Removes and installs valve springs.
3454
90-8M0060785 DECEMBER 2011 Page 4B-3

Cylinder Head
Cylinder Head
6
49000
Page 4B-4 90-8M0060785 DECEMBER 2011

Cylinder Head
Cylinder Head
Torque
1 12 Screw (M6 x 25) 10 88.5
2 1 Camshaft cover
3 1 Seal
First 15 132.7
4 10 Screw (M10 x 95) Second 30 22.1
5 3 Screw (M6 x 40) 10 88.5
6 1 Gasket
90-8M0060785 DECEMBER 2011 Page 4B-5

Cylinder Head
Cylinder Head and Valve Train Components

7
14
8
15 1
23
2
16
34
4 20 21 18
19 17 13
22
11
12
23
3
8
7 10
9
6
5
24
27
33
31 32
26 30
28
27 25
49001
29
Page 4B-6 90-8M0060785 DECEMBER 2011

Cylinder Head
Cylinder Head and Valve Train Components

Torque
1 1 Cylinder head
2 4 Exhaust valve seat
3 4 Intake valve seat
4 8 Valve guide
5 1 Plug (30 mm) 55 40.5
6 1 O‑ring
7 2 Plug (24 mm) 55 40.5
8 2 O‑ring
9 1 Plug (10 mm) 9 79.6
10 1 O‑ring
11 5 Camshaft cap
First 6 53
12 10 Screw (M6 x 36)
Final 12 106
13 8 Rocker assembly
14 1 Fitting
15 4 Exhaust valve
16 4 Intake valve
17 8 Ball stud
18 8 Valve retainer
19 8 Valve spring retainer lock (2 each)
20 8 Valve guide seal
21 8 Valve spring
22 1 Camshaft
23 2 Dowel pin
24 1 Timing chain tensioner guide
25 1 Timing chain fixed guide
26 1 Camshaft gear
27 2 Shoulder screw (M8 x 37) 24 17.7
28 1 Timing chain
First 45 33.2
29 1 Screw (M12 x 40) (left‑hand thread)
30 1 Tensioner
31 1 O‑ring
32 1 Cover
33 2 Screw (M6 x 25) 10 88.5
34 6 Plugs (10 mm) 9 79.6
90-8M0060785 DECEMBER 2011 Page 4B-7

Cylinder Head
Cylinder Head Service Recommendations

All engines, from a single cylinder low horsepower to a multicylinder high‑performance racing engine, require frequent
maintenance and inspection schedules because of the extreme duty cycles and related stress these products endure. Failure to
follow the maintenance and service schedule could lead to catastrophic engine failure and increased owner expense.
The cylinder head is the most important component of the engine. It has extremely close tolerance machined components that
must be repaired by an accomplished Master Technician with experience servicing high‑performance engines. A skilled
machine shop that is familiar with automotive engine machining techniques, must be utilized when the cylinder head requires
any type of machining or clearance correction repair. Damage to the cylinder head combustion chamber area from a
component failure, debris, or improper machining, will alter the emissions output of the engine and may require the cylinder
head be replaced instead of repaired. Careful attention to details, proven repair techniques, and factory supplied high quality
parts are required to restore this engine to the original factory emissions and performance output.
IMPORTANT: The cylinder head is machined to extremely close tolerances and should not be modified by inexperienced
personnel. Cutting the valve seat without close attention to detail, can change the combustion chamber area where the engine
is not within the factory emissions specification and may effect the engine's performance.
Cylinder Head Disassembly

Camshaft Removal
NOTE: Refer to Section 4A ‑ Cylinder Block/Crankcase for the removal of the cylinder head from the cylinder block.
IMPORTANT: Removal of the camshaft requires the procedure to be followed exactly. Failure to follow the removal procedure
of the camshaft caps, could damage the camshaft, camshaft caps, and the cylinder head camshaft bearing area.
1. Place the cylinder head onto a support platform so the valves will not contact the workbench or support platform.
2. Use the hex on the camshaft to rotate the camshaft so the camshaft gear pin is located at the 9 o'clock position. This
allows the camshaft to have minimal valve spring tension when removing the camshaft caps.
a - Camshaft gear pin at 9 o'clock position
48298
3. Loosen all of the camshaft caps 1/4 turn, starting at the top number 1 camshaft cap, and working sequentially towards
camshaft cap number five.
4. Remove camshaft caps 1, 4, and 5.
5 4 3 1
2
48299
5. Loosen the screws from camshaft cap 2 and 3, 1/4 turn each until the camshaft does not have any valve spring tension on
it.
Page 4B-8 90-8M0060785 DECEMBER 2011

Cylinder Head
IMPORTANT: Rotating the camshaft cap screws more than 1/4 turn, could cause damage to the camshaft, camshaft caps,
and the cylinder head camshaft bearing area.
a - Cap #3
b - Cap #2
a b
48300
6. Remove the camshaft caps and lift the camshaft off the cylinder head.
7. Remove the rocker arms.
48301
8. Loosen the ball stud nut and remove the ball stud.
a a - Ball stud
b - Ball stud nut
48302
9. Compress the valve springs with the valve spring compressor tool and remove the valve spring retainer locks.
a a - Valve spring compressor tool

b - Valve spring retainer locks
48303
90-8M0060785 DECEMBER 2011 Page 4B-9

Cylinder Head
10. Remove the valve spring and retainer.
11. Push the valve out of the cylinder head.
12. Remove the valve seal with a pair of pliers.
48310
Cylinder Head Galley Plug Removal

1. Remove all of the oil and water galley plugs from the cylinder head.
NOTE: It may be necessary to lightly tap on the galley plugs with a brass drift and hammer to break the galley plug seal.
2. Remove the O‑rings from the galley plugs and discard the O‑rings.
c a - Water galley access

plug (30 mm)
b - Water galley plug
(24 mm)
b c - Oil galley plug (10 mm)
a
48322
Cleaning, Inspection, and Repair

Camshaft
1. Carefully inspect the camshaft lobe surfaces for cracks, pits, scoring, or corrosion. If any of these conditions are found,
replace the camshaft.
2. Measure the camshaft lobe at its maximum valve lift location. Replace the camshaft if the dimensions are out of
specification.
21391
Page 4B-10 90-8M0060785 DECEMBER 2011

Cylinder Head
Camshaft Lobe
Intake 48.05 mm (1.892 in.)
3. Measure all of the camshaft bearing journals. Replace the camshaft if the journal dimensions are out of specification.
21393
Camshaft Bearing
Journal diameter 28.97 ± 0.01 mm (1.1405 ± 0.0004 in.)
Valve Specifications
Intake Valve
IMPORTANT: If the intake valve does not measure to the following specifications, it must be replaced.
Intake Valve Specifications

125.14 ± 0.30 mm
Height (a)
(4.9267 ± 0.0118 in.)
7.966 ± 0.10 mm
Valve stem diameter (b)
(0.313 ± 0.0039 in.)
Valve face angle (c) 45°
Intake valve
Outside diameter (d) 50.8 ± 0.13 mm (2.0 ± 0.005 in.)
0.38 ± 0.2 mm
Valve margin width (e)
(0.0149 ± 0.007 in.)
Valve stem service limit runout (measured at valve
0.038 mm (0.0015 in.)
face)
e
a b
c
d 47971
90-8M0060785 DECEMBER 2011 Page 4B-11

Cylinder Head
Exhaust Valve
Exhaust Valve Specifications
126.29 ± 0.30 mm
Height (a)
(4.9720 ± 0.0118 in.)
7.966 ± 0.10 mm
Valve stem diameter (b)
(0.313 ± 0.0039 in.)
Valve face angle (c) 45°
Exhaust valve
Outside diameter (d) 39.4 ± 0.13 mm (1.55 ± 0.005 in.)
1.46 ± 0.35 mm
Valve margin width (e)
(0.0574 ± 0.0137 in.)
Valve stem service limit runout (measured at valve
0.038 mm (0.0015 in.)
face)
e
a
b c
d 47969
Valve Springs
The engine is an interference valve train design. A weak valve spring could possibly cause extensive damage to the engine.
Check the height of each spring. Replace all the valve springs if any spring is out of specification.
48325
Valve Spring
Height (uncompressed) 57.08 ± 0.25 mm (2.247 ± 0.0098 in.)
Page 4B-12 90-8M0060785 DECEMBER 2011

Cylinder Head
Compress each valve spring to the specified height. If the amount of spring force is not within the specified range, replace the
valve spring.
48846
Spring Force
Compressed to 50.24 mm (1.977 in.) 350 ± 25 N (78.68 ± 5.62 lbf)
Compressed to 36.78 mm (1.448 in.) 1039 ± 45 N (233.57 ± 10.11 lbf)
Cylinder Head
1. Inspect the cylinder head for mineral deposits/corrosion in the water passageways, clean any deposits/corrosion observed.
2. Thoroughly flush the oil galley with a clean solvent.
NOTE: Use a bore brush to clean the oil galley of sludge and to dislodge any possible debris.
3. Inspect the cylinder head for carbon deposits in the combustion chamber. Use a round scraper to clean away deposits. Be
careful not to scratch or remove material.
NOTE: Use plastic media or baking soda to pressure blast (remove) deposits without damaging the combustion area.
4. Measure the cylinder head for any warp. Replace the cylinder head if out of specification.
NOTE: Use a straight edge and a feeler gauge to inspect the cylinder head for any indication of warp.
48320
Cylinder Head
Maximum deck warp 0.1 mm (0.0039 in.)
90-8M0060785 DECEMBER 2011 Page 4B-13

Cylinder Head
5. Measure the cylinder head camshaft center bearing thrust face. Replace the cylinder head if out of specification.
a
a - Cylinder head camshaft center
bearing thrust face
48350
Cylinder Head
Camshaft thrust face 19.975 ± 0.025 mm (0.7864 ± 0.0009 in.)
6. Install the camshaft caps in their correct location. Tighten the camshaft cap screws to the specified torque.

Camshaft cap screw 12 106
7. Measure the inside dimension of the camshaft bearing journal. Replace the cylinder head if the dimension is out of
specification.
a - Camshaft bearing cap inside dimension
a
21395
Camshaft Bearing Journal

Inside diameter 29.000–29.021 mm (1.1417–1.1425 in.)
8. Measure the combustion chamber height. Replace the cylinder head if the dimension is out of specification.
a - Combustion chamber height
49358
Combustion Chamber Specification

Combustion chamber height (minimum) 7 mm (0.275 in.)
Valve Guides
1. Clean the valve guides with a solvent and valve guide brush to remove any varnish deposits.
Page 4B-14 90-8M0060785 DECEMBER 2011

Cylinder Head
2. Measure the valve guide bore with a valve guide bore gauge. If the valve guide is out of specification, replace the valve
guide.
a - Valve guide bore

a
20975
Valve Guide Bore

Intake and exhaust 8.001–8.021 mm (0.3149–0.3157 in.)
VALVE GUIDE REPLACEMENT

NOTE: Inexperienced personnel should not attempt to replace the valve guide. A reputable engine machine shop will have the
tools to replace the valve guides and ream the guides to proper tolerance.
IMPORTANT: The valve guide must be removed and installed after heating the head to a minimum temperature of 350°. Use a
pneumatic impact hammer to remove and install the valve guide. Check the valve guide for proper clearances after installation.
a - Valve guide height
48351
Cylinder Head
Valve guide height 24.9 ± 0.25 mm (0.980 ± 0.0098 in.)
Valve Stem to Valve Guide Clearance

Intake and exhaust 0.025–0.065 mm (0.001–0.0025 in.)
Valve Seat Reconditioning

The cylinder head is the most important component of the engine. It has extremely close tolerance machined components that
must be repaired by an accomplished Master Technician with experience servicing high‑performance engines. A skilled
machine shop that is familiar with automotive engine machining techniques, must be utilized when the cylinder head requires
any type of machining or clearance correction repair. Damage to the cylinder head combustion chamber area from a
component failure, debris, or improper machining, will alter the emissions output of the engine and may require the cylinder
head be replaced instead of repaired. Careful attention to details, proven repair techniques, and factory supplied high quality
parts are required to restore this engine to the original factory emissions and performance output.
IMPORTANT: The cylinder head is machined to extremely close tolerances and should not be modified by inexperienced
personnel. Cutting the valve seat without close attention to detail, can change the combustion chamber area where the engine
is not within the factory emissions specification and may effect the engine's performance.
1. Clean the carbon deposits from the combustion chambers and valve seats. Check the valve seats for pitting.
2. Minimal and light pitting should be cleaned up with 600 grit lapping compound.
IMPORTANT: The exhaust valve and seat should be replaced if the pitting cannot be cleaned up with minimal amount of
lapping the valve to the seat. If the valve seat is replaced, the top cut of the valve seat must not go below or alter the
factory machining of the combustion chamber.
3. Apply a thin, even layer of mechanic's bluing dye (Dykem) onto the valve seat.
4. Insert the valve into the valve guide and lap the valve slowly on the valve seat.
90-8M0060785 DECEMBER 2011 Page 4B-15

Cylinder Head
5. Remove the valve and measure the valve seat contact pattern width.
a- Correct valve seat contact area

b- Valve seat too high
a b c d 20969 c- Valve seat too low
d- Valve seat contact too wide
Valve Face Angle

Intake and exhaust 45°
Valve Seat Angles

Intake 30°, 44°, 60°
Exhaust 25°, 44°, 65°
Cylinder Head Assembly

Cylinder Head Galley Plug Installation
1. Install new O‑rings on the galley plugs.
2. Lubricate the threads of the galley plugs with Synthetic Blend 4‑Stroke Outboard Oil 25W‑40.
3. Install all the oil and water galley plugs. Tighten the galley plugs to the specified torque.
c a - Water galley access

plug (30 mm)
b - Water galley plug
(24 mm)
b c - Oil galley plug (10 mm)
a
48322

139 Galley plug threads 92-858052K01
Outboard Oil 25W-40

Water galley access plug (30 mm) 55 40.5
Water galley plug (24 mm) 55 40.5
Oil galley plug (10 mm) 9 79.6
Page 4B-16 90-8M0060785 DECEMBER 2011

Cylinder Head
Valve Installation
1. Lubricate the valve guide seal with Synthetic Blend 4‑Stroke Outboard Oil 25W‑40.
139
4831

139 Valve guide seal 92-858052K01
Outboard Oil 25W-40
2. Install the valve guide seal onto the valve guide. Push on the valve guide seal until it is seated on the cylinder head.
48337
3. Lubricate the valve stem with a high quality engine assembly lubricant and push the valve through the valve guide seal.
Engine assembly lubricant can be purchased locally.
4. Place the valve spring and valve spring retainer over the valve stem.
5. Compress the valve spring with a valve spring compressor.
IMPORTANT: Use caution when compressing the valve spring. Do not damage the valve, valve spring retainer, or the
cylinder head.
b a- Valve spring retainer lock (2 each)

a
c b- Valve spring retainer
c- Valve spring
d
d- Valve guide seal
e- Valve (intake and exhaust)
48338
90-8M0060785 DECEMBER 2011 Page 4B-17

Cylinder Head
6. Place the valve spring retainer locks onto the valve. A small amount of 2‑4‑C with PTFE applied to the valve area will help
retain the locks onto the valve.
a a - Valve spring compressor tool

b - Valve spring retainer locks
48303

95 2-4-C with PTFE Installing valve spring retainer locks 92-802859A 1
7. Release the valve spring compressor.
8. Continue to assemble all valves onto the cylinder head.
Camshaft Installation
IMPORTANT: Installation of the camshaft requires the procedure to be followed exactly. Failure to follow the installation
procedure of the camshaft caps, could damage the camshaft, camshaft caps, and the cylinder head camshaft bearing area.
1. Lubricate the ball stud assembly threads with Synthetic Blend 4‑Stroke Outboard Oil 25W‑40 and install onto the cylinder
head.

139 Ball stud assembly threads 92-858052K01
Outboard Oil 25W-40
2. Verify the ball stud is threaded completely in to minimize valve spring compression while installing the camshaft.
a a - Ball stud
b - Ball stud nut
48302
3. Apply Synthetic Blend 4‑Stroke Outboard Oil 25W‑40 to the roller bearing on both sides of the rocker arm.
4. Apply engine assembly lubricant to the ball stud end and valve end of the rocker arm. Engine assembly lubricant can be
purchased locally.
b a - Engine assembly lubricant (obtain locally)

a
b - Synthetic Blend 4‑Stroke Outboard Oil 25W‑40
a
48339
Page 4B-18 90-8M0060785 DECEMBER 2011

Cylinder Head

139 Rocker arm roller bearing 92-858052K01
Outboard Oil 25W-40
5. Install the rocker arm onto the ball stud and valve.
48301
6. Apply engine assembly lubricant to the camshaft lobes, journals, and thrust face. Engine assembly lubricant can be
purchased locally.
7. Install the camshaft so the camshaft gear pin is located at the 9 o'clock position. This allows the camshaft to have minimal
valve spring tension when installing and tightening the camshaft cap screws.
48314
8. Apply engine assembly lubricant to the cylinder head camshaft caps. Engine assembly lubricant can be purchased locally.
9. Install camshaft cap 2 and 3. Verify the arrow on the cap points towards the top of the cylinder head.
IMPORTANT: The camshaft cap screws and the threads in the head must be thoroughly cleaned of debris and oil. The
camshaft cap screws must be completely dry when applying the torque.
10. Ensure the camshaft caps are parallel with the cylinder head mating surface while tightening the screws 1/4 turn each.
Continue to tighten the screws 1/4 turn each until the camshaft caps are seated on the cylinder head. Do not torque the
screws.
IMPORTANT: Rotating the camshaft cap screws more than 1/4 turn, could cause damage to the camshaft, camshaft caps,
and the cylinder head camshaft bearing area.
a - Cap #3
b - Cap #2
a b
48300
11. Install camshaft caps 1, 4, and 5. Tighten the screws until the caps are seated on the cylinder head.
90-8M0060785 DECEMBER 2011 Page 4B-19

Cylinder Head
12. Tighten the camshaft cap screws in two stages to the specified torque in the sequence shown.
5 1 3 7
9
10 4 8
6
2
48318

First 6 53
Camshaft cap screws (M6 x 35)
Final 12 106
Adjusting Valve Clearance

IMPORTANT: Setting the clearance on the bench will not necessarily match the final specification after the cylinder head has
been installed onto the cylinder block and torqued to specification. It is expected the valve clearance will change to a value that
minimizes the amount of additional adjustment.
IMPORTANT: The clearance specifications apply when the ball stud locknut is tightened to the specified torque.
IMPORTANT: When measuring clearance with a feeler gauge blade you must change sizes until you feel a firm drag when
pushing and pulling on the gauge. Verify your results by trying the next size larger blade. It must be much more difficult or
nearly impossible to enter the gap. Next, try the next size smaller blade. It must have little or no drag. If your results are
different, your technique is incorrect. Common mistakes are twisting and flexing the blade, and failing to hold the blade
perpendicular to the gap.
1. Rotate the camshaft so the lobe is 180° from the rocker arm roller.
2. Insert a feeler gauge between the roller and the cam. Increase the ball stud height so there is a slight drag on the gauge.
3. Secure the ball stud and tighten the locknut to the specified torque.
a - Feeler gauge
a b - Ball stud
c - Locknut
b
c
48342
Camshaft to Roller Clearance Specifications

Intake valve 0.0762 mm (0.003 in.)
Exhaust valve 0.254 mm (0.010 in.)

Ball stud locknut 20 177
Page 4B-20 90-8M0060785 DECEMBER 2011

Cylinder Head
4. Check the clearance after tightening the locknut to the specified torque. Adust the clearance as required.
90-8M0060785 DECEMBER 2011 Page 4B-21

Cylinder Head
Notes:
Page 4B-22 90-8M0060785 DECEMBER 2011

Lubrication
Powerhead
Section 4C - Lubrication
Table of Contents
Lubrication System Specifications..................................... 4C-2 Disassembly and Inspection.......................................4C-4
Oil Flow Diagram............................................................... 4C-3 Assembly.................................................................... 4C-4
Oil Pump ........................................................................... 4C-4
4
C
90-8M0060785 DECEMBER 2011 Page 4C-1

Lubrication

Engine capacity with filter replacement 6 liters (6.3 US qt)
Oil filter P/N 35‑877761K1
Oil pressure

Grease
139 Oil pump 92-858052K01
Outboard Oil 25W-40
Page 4C-2 90-8M0060785 DECEMBER 2011

Lubrication
Oil Flow Diagram

a e f
h
g
b c i
d j
49627
a- Cylinder head
b- Ball stud adjusters
c- Camshaft
d- Camshaft chain tensioner
e- Cylinder block
f- Crankshaft
g- Connecting rods
h- Balance shaft chain tensioner
i- Balance shaft
j- Oil filter
k- Oil pump
l- Oil pressure relief valve
m- Adapter plate
n- Oil sump
90-8M0060785 DECEMBER 2011 Page 4C-3

Lubrication
Oil Pump
Disassembly and Inspection
The oil pump is not a serviceable part, but should be disassembled for inspection when the cylinder head or cylinder block is
repaired. The oil pump should also be disassembled and inspected if the engine was submerged in water.
1. Remove the seven screws securing the oil pump cover to the oil pump housing. Remove the cover.
48353
2. Remove the inner drive gerotor and outside gerotor.

b - Outside gerotor
a
46329
3. Inspect all areas where the gerotors contact each other and where the gerotors contact the oil pump housing and cover.
The contact areas should be smooth without grooves, galling, or evidence of corrosion.
4. A pressure relief valve is incorporated into the oil pump housing. It should never be removed from the housing to modify
the spring pressure. If significant debris was found in the oil pump gerotor area, the oil pump must be replaced as an
assembly.
Assembly
1. Wash the housing, cover, and gerotors with a mild solvent. Use compressed air to dry the components.
2. Inspect the seal lips for damage. Replace as needed. Lubricate the seal lips with Engine Coupler Spline Grease.

Grease
3. Generously lubricate the gerotors and the areas where the gerotors contact the housing and cover with Synthetic Blend
4‑Stroke Outboard Oil 25W‑40.

139 Oil pump 92-858052K01
Outboard Oil 25W-40
4. Install the outside gerotor into the oil pump housing with the dot side up.
Page 4C-4 90-8M0060785 DECEMBER 2011

Lubrication
5. Install the inner drive gerotor with the dot side up.

b - Outside gerotor
a
46329
6. Align the oil pump cover with the oil pump housing pins and install the oil pump cover.
7. Secure the oil pump cover with seven screws. Tighten the screws to the specified torque in the sequence shown.
4
3
1
5
2
46327
6

Oil pump cover screws (7) 4 35.4
90-8M0060785 DECEMBER 2011 Page 4C-5

Lubrication
Notes:
Page 4C-6 90-8M0060785 DECEMBER 2011

Cooling
Powerhead
Section 4D - Cooling
Table of Contents
Cooling Specifications....................................................... 4D-2 Thermostat.........................................................................4D-7
Cooling Components......................................................... 4D-4 Thermostat Removal.................................................. 4D-7
Water Flow Diagram.......................................................... 4D-6 Thermostat Installation............................................... 4D-7
4
D
90-8M0060785 DECEMBER 2011 Page 4D-1

Cooling
Cooling system Water‑cooled ‑ thermostat control
Water pressure
At 5800 RPM (WOT) 80–300 kPa (11.6–43.5 psi)
Valve stroke (minimum) at full open temperature 7.62 mm (0.30 in.)
Thermostat Start to opening temperature 46.1–51.7 °C (115–125 °F)
Full open temperature 65.6 °C (150 °F)

95 2-4-C with PTFE Thermostat housing O-ring 92-802859A 1
Special Tools
8M0046124
Harness
41993
Page 4D-2 90-8M0060785 DECEMBER 2011

Cooling
Notes:
90-8M0060785 DECEMBER 2011 Page 4D-3

Cooling
Cooling Components
30 29
31 2 3 4
18
1
5
24 7 6
28
22
23 8 6
25
26 29
27
13
14
12
15
10 9
11
16
18
19
18
18 18
17
20
18
48998
21
Page 4D-4 90-8M0060785 DECEMBER 2011

Cooling
Cooling Components
Torque
1 1 Plastic fitting
3 1 Thermostat dump hose
4 1 Water pump indicator hose
5 2 Plastic retainer
6 4 Plastic screw
9 1 Water pump indicator
10 1 O‑ring
11 1 Screw (M6 x 16) 6 53.1
13 1 Screw (M6 x 25) 6 53.1
14 1 Fitting
15 2 O‑ring
16 1 Fitting
17 1 Hose
18 5 Cable tie
19 1 Hose
20 1 Hose
21 1 Fitting
22 1 Fitting
23 2 Clamp
24 1 Flush hose
25 1 Flushing attachment
27 1 Hose
29 4 Screw (M6 x 25) 8 70.8
30 1 Thermostat
31 1 O‑ring
90-8M0060785 DECEMBER 2011 Page 4D-5

Cooling
Water Flow Diagram

12
8
10
11
8 10
9
6 13
14
15
4
2
49628
1- Water intake
2- Water tube
3- Driveshaft housing
4- Fuel supply module
5- Strainer
6- Adapter
7- Exhaust manifold
8- Cylinder head
9- Water pump indicator hose
Page 4D-6 90-8M0060785 DECEMBER 2011

Cooling
10 - Cylinder block
11 - Water dump hose
12 - Thermostat housing
13 - Oil cooler
14 - Oil sump
15 - Cylinder block water drain
Thermostat
Thermostat Removal
The thermostat can be monitored for proper operation with the CDS G3 tool.

8M0046124
Harness
1. Remove the bolts securing the thermostat housing to the cylinder block.
2. With a twisting motion, remove the thermostat housing from the cylinder block.
48162
3. Rotate the thermostat housing to access the thermostat.

4. Push down on the thermostat spring retainer and rotate the retainer counterclockwise.
5. Remove the spring and thermostat.
b a - Thermostat spring retainer (rotate counterclockwise)

b - Thermostat
48163
6. Inspect the thermostat and spring for failure or corrosion. Replace any items that are damaged.
Thermostat Installation
1. Install the narrow end of the thermostat into the thermostat housing.
2. Install the narrow end of the thermostat spring onto the thermostat.
90-8M0060785 DECEMBER 2011 Page 4D-7

Cooling
3. Install the thermostat spring retainer onto the spring.
d a- Thermostat housing
b- Thermostat
c
c- Thermostat spring
b d- Thermostat spring retainer
a
48164
4. Push down on the thermostat spring retainer and rotate the retainer clockwise to lock it onto the thermostat housing.
48165
5. Install the O‑ring onto the thermostat housing. Lubricate the O‑ring with 2‑4‑C with PTFE.
48166

95 2-4-C with PTFE Thermostat housing O-ring 92-802859A 1
Page 4D-8 90-8M0060785 DECEMBER 2011

Cooling
6. Install the thermostat housing onto the cylinder block and secure with two M6 x 25 screws. Tighten the screws to the
specified torque.
48162

Screws (M6 x 25) 8 70.8
90-8M0060785 DECEMBER 2011 Page 4D-9

Cooling
Notes:
Page 4D-10 90-8M0060785 DECEMBER 2011

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Throttle Linkage

Section 7A - Throttle Linkage
Table of Contents
Intake Manifold Components............................................. 7A-4 Throttle Link Installation..................................................... 7A-7
Throttle Link Removal ....................................................... 7A-6
7
A
90-8M0060785 DECEMBER 2011 Page 7A-1

Throttle Linkage

Throttle link actuator shoulder screw threads
66 Loctite 242 Threadlocker 92-809821
Throttle lever shoulder screw threads
Throttle link actuator shoulder screw and washers
95 2-4-C with PTFE 92-802859A 1
Throttle lever shoulder screw and washers
Page 7A-2 90-8M0060785 DECEMBER 2011

Throttle Linkage
Notes:
90-8M0060785 DECEMBER 2011 Page 7A-3

Throttle Linkage

1
5
6
4
8
9
23
22 1
12
11
17
16 20
10 15
21 3
18
13 14
20
19
17
16
15 49355
Page 7A-4 90-8M0060785 DECEMBER 2011

Throttle Linkage

Torque
1 6 Screw (M6 x 20) 8 70.8
2 1 Throttle body assembly
3 1 Intake manifold
4 4 Seal
5 1 Seal
6 1 Link rod
7 1 Socket
8 5 Retainer
9 11 Screw (M6 x 40) 10 88.5
10 1 Screw (M4 x 16) 6 53.1
11 1 Bracket
12 1 Manifold absolute pressure sensor
13 1 Plastic screw
14 1 Clip
15 2 Shoulder screw 10 88.5
16 2 Wave washer
17 2 Washer
18 1 Throttle lever
19 1 Return spring
20 2 Washer
21 1 Throttle link actuator
22 1 Link rod retainer
23 1 Idle air control
90-8M0060785 DECEMBER 2011 Page 7A-5

Throttle Linkage
Throttle Link Removal

1. Remove the screw securing the throttle lever to the intake manifold.
e
b
a
f
d
c
48202
a- Shoulder screw
b- Wave washer
c- Washer
d- Throttle lever
e- Return spring
f- Washer
48203
3. Remove the screw securing the throttle link actuator to the intake manifold.
Page 7A-6 90-8M0060785 DECEMBER 2011

Throttle Linkage
4. Remove the throttle link rod actuator assembly from behind the intake manifold.
c
a b
d e
48206
a- Shoulder screw
b- Wave washer
c- Washer
d- Throttle link actuator
e- Washer
Throttle Link Installation

1. Measure the link rod length. Adjust if necessary.
a
48704
a - 415.1 mm (16.34 in.)
2. Install the throttle link rod onto the throttle link actuator.
3. Install the wave washer onto the throttle link actuator shoulder screw.
4. Install the washer onto the throttle link actuator shoulder screw.
screw threads.
6. Insert the shoulder screw with the washers through the throttle link actuator.
90-8M0060785 DECEMBER 2011 Page 7A-7

Throttle Linkage
7. Install the washer onto the shoulder screw threaded end.
a- Shoulder screw
b- Wave washer
f c- Washer
e d- Throttle link actuator
e- Throttle link rod
f- Washer
d
b
48207
a

95 2-4-C with PTFE Throttle link actuator shoulder screw and washers 92-802859A 1

66 Loctite 242 Threadlocker Throttle link actuator shoulder screw threads 92-809821
9. Guide the throttle link rod behind the intake manifold and secure the throttle link actuator to the intake manifold. Tighten the
shoulder screw to the specified torque.
a a - Throttle link rod

b - Shoulder screw
48208

Page 7A-8 90-8M0060785 DECEMBER 2011

Throttle Linkage
48203
11. Install the return spring into the throttle lever.
a - Long end
b - Short end
a b
48210
12. Install the wave washer onto the throttle lever shoulder screw.
13. Install the washer onto the throttle lever shoulder screw.
screw threads.
15. Insert the shoulder screw with the washers through the throttle lever.
a- Shoulder screw
e b- Wave washer
c- Washer
d- Throttle lever
e- Washer
d
c
b
a 48211

95 2-4-C with PTFE Throttle lever shoulder screw and washers 92-802859A 1
90-8M0060785 DECEMBER 2011 Page 7A-9

Throttle Linkage

66 Loctite 242 Threadlocker Throttle lever shoulder screw threads 92-809821
17. Verify the throttle actuator roller is engaged with the throttle lever.
18. Align the long end of the spring with the boss on the intake manifold.
19. Secure the throttle lever to the intake manifold block with the shoulder screw. Tighten the shoulder screw to the specified
torque.
a - Throttle actuator roller

b b - Long end of the spring
c - Shoulder screw
c
48212

Page 7A-10 90-8M0060785 DECEMBER 2011

Shift Linkage

Section 7B - Shift Linkage
Table of Contents
Shift Linkage Components.................................................7B-4 Shift Bracket Disassembly.......................................... 7B-7
Shift Bracket Removal....................................................... 7B-6 Shift Bracket Assembly...............................................7B-8
Shift Bracket Disassembly and Assembly..........................7B-7 Shift Bracket Installation.................................................... 7B-9
7
B
90-8M0060785 DECEMBER 2011 Page 7B-1

Shift Linkage

Shift link pin
95 2-4-C with PTFE Cantilever actuator 92-802859A 1
Bronze bushing
Page 7B-2 90-8M0060785 DECEMBER 2011

Shift Linkage
Notes:
90-8M0060785 DECEMBER 2011 Page 7B-3

Shift Linkage
Shift Linkage Components

1
2
3 6 7
8
4
1
5 6
5 9
5
10 11
12
13
14
17 15
16
48996
Page 7B-4 90-8M0060785 DECEMBER 2011

Shift Linkage
Shift Linkage Components

Torque
1 2 Latch
2 1 E‑ring
3 1 Roller
4 1 Plastic washer
5 3 Screw (M6 x 25) 10 88.5
6 2 Cup
7 1 Shift position sensor
8 1 Screw (M4 x 13) 8 70.8
9 1 Bracket
10 1 Bow tie clip
11 1 Locknut (M6) 6 53.1
12 1 Washer
13 1 Shift link
14 1 Bronze bushing
15 1 Shift shaft
16 1 Bushing (bronze)
17 1 Cantilever actuator
90-8M0060785 DECEMBER 2011 Page 7B-5

Shift Linkage
Shift Bracket Removal

1. Remove the lower starboard cowl. Refer to Section 4A ‑ Lower Cowl.
3. Cut the two cable ties securing the engine harness to the shift bracket.
4. Remove the speedometer hose from the retainer on the bracket.
c d
a
49513
a- Retainer securing speedometer hose

b- Engine harness connector on shift position sensor
c- Cable tie
d- Cable tie (not visible)
5. Remove the locknut and washer securing the shift link to the shift shaft.
6. Lift the shift link off the upper shift shaft and remove the bronze bushing.
a- Shift link
b c b- Washer
a d
c- Locknut
d- Bronze bushing
e- Upper shift shaft
49514
Page 7B-6 90-8M0060785 DECEMBER 2011

Shift Linkage
7. Remove the three screws securing the shift bracket to the powerhead.
49515
Shift Bracket Disassembly and Assembly

Shift Bracket Disassembly
1. Remove the screw securing the shift position sensor to the shift bracket. Lift the shift position sensor off the antirotation pin.
a - Screw securing the shift position sensor

b - Antirotation pin
b 49516
2. Remove the E‑ring securing the roller onto the shift link pin.
3. Remove the roller. The shift link and the cantilever actuator can be removed from the shift bracket.
a - Roller
b - E‑ring
c - Cantilever actuator
c
b
49518
90-8M0060785 DECEMBER 2011 Page 7B-7

Shift Linkage
Shift Bracket Assembly

1. Install the plastic washer with the raised side up onto the shift link pin.
a
49519
a - Plastic washer with the raised side up
2. Apply 2‑4‑C with PTFE to the shift link pin and install the shift link onto the shift bracket.
3. Install the roller with the beveled edge up onto the shift link pin.
4. Secure the roller to the shift link pin with the E‑ring.
a - Roller with the beveled edge up

b - E‑ring
a
b
49520

95 2-4-C with PTFE Shift link pin 92-802859A 1
5. Apply 2‑4‑C with PTFE to the area where the cantilever actuator will be installed.
6. Install the cantilever actuator onto the shift bracket and shift lever.
a - Apply 2‑4‑C with PTFE
49521
Page 7B-8 90-8M0060785 DECEMBER 2011

Shift Linkage

95 2-4-C with PTFE Cantilever actuator 92-802859A 1
7. Secure the cantilever actuator and install the shift position sensor onto the cantilever actuator and shift bracket antirotation
pin.
8. Secure the shift position sensor with a M4 x 13 screw. Tighten the screw to the specified torque.
a - Screw securing the shift position sensor

b - Antirotation pin
b 49516

Screw (M4 x 13) 8 70.8
Shift Bracket Installation

1. Apply 2‑4‑C with PTFE to the bronze bushing and install onto the upper shift shaft.
a a - Bronze bushing
49524

95 2-4-C with PTFE Bronze bushing 92-802859A 1
90-8M0060785 DECEMBER 2011 Page 7B-9

Shift Linkage
2. Install the shift bracket and secure with three M6 x 25 screws. Tighten the screws to the specified torque.
49515

Screws (M6 x 25) (3) 10 88.5
3. Install the shift link onto the upper shift shaft and secure with a washer and locknut. Tighten the locknut to the specified
torque.
a- Shift link
b c b- Washer
a d
c- Locknut
d- Bronze bushing
e- Upper shift shaft
49514

Nut 6 53.1
4. Connect the engine harness connector to the shift position sensor.

5. Secure engine harness to the shift bracket with two cable ties.
6. Secure the speedometer hose with the retainer on the bracket.
7. Install the lower starboard cowl. Refer to Section 4A ‑ Lower Cowl.
Page 7B-10 90-8M0060785 DECEMBER 2011

Cowl Latch

Section 7C - Cowl Latch
Table of Contents
Rear Cowl Latch Removal................................................. 7C-2 Rear Cowl Latch Installation.............................................. 7C-3
7
C
90-8M0060785 DECEMBER 2011 Page 7C-1

Cowl Latch

95 2-4-C with PTFE Cowl latch hinge pin pivot plastic bushings 92-802859A 1
Rear Cowl Latch Removal

2. Insert a pry tool between the latch handle and the hinge pin. Disengage the hinge pin from the latch handle.
3. Remove the hinge pin by pulling it down after it is disengaged from the latch handle.
4. Pull the left side of the latch handle to clear the pivot area and remove the latch handle from the link rod.
a b
48974
a - Hinge pin
b - Link rod
5. Disengage the link rod retainer and remove the link rod from the rear cowl latch assembly.
a - Link rod retainer

a
48975
6. Remove the link rod and seal.
Page 7C-2 90-8M0060785 DECEMBER 2011

Cowl Latch
7. Remove the two M6 x 25 screws securing the rear cowl latch and remove the latch.
a b a - Screws (M6 x 25)

b - Seal
c - Link rod
49270
Rear Cowl Latch Installation

1. Verify the link rod and seal are installed onto the cowl.
2. Verify the two hinge pin pivot plastic bushings are installed. Lubricate the bushings with 2‑4‑C with PTFE.
3. Install the rear cowl latch and secure with two washers and M6 x 25 screws. Tighten the screws to the specified torque.
b a- Plastic bushings
b- Washer and M6 x 25 screw (2 each)
c- Seal
d- Link rod
a
d
48976

95 2-4-C with PTFE Cowl latch hinge pin pivot plastic bushings 92-802859A 1

Screw (M6 x 25) 10 88.5
4. Insert the link rod into the rear cowl latch assembly and secure with the link rod retainer.
a - Link rod retainer

a
48975
90-8M0060785 DECEMBER 2011 Page 7C-3

Cowl Latch
5. Install the latch handle onto the link rod.
6. Align the latch handle hinge pin holes with the plastic bushings.
7. Insert the hinge pin into the latch handle and push the hinge pin through the other side of the latch handle.
8. Snap the hinge pin into the latch handle.
49271
9. Install the top cowl.
Page 7C-4 90-8M0060785 DECEMBER 2011

4s Efi 150 3.0 Litre

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4s Efi 150 3.0 Litre

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150 FourStroke

Serial Number 1B905505 and Above

www.mercurymarine.com.au www.mercurymarine.com www.marinepower.com

IMPORTANT: Identifies information essential to the successful completion of the task.

Cleanliness and Care of Product

© 2011, Mercury Marine

IMPORTANT: Identifies information essential to the successful completion of the task.

Cleanliness and Care of Product

© 2011, Mercury Marine

90-8M0060785 DECEMBER 2011 Page 1A-1

Page 1A-2 90-8M0060785 DECEMBER 2011

Charging and Starting Specifications

90-8M0060785 DECEMBER 2011 Page 1A-3

Fuel System Specifications

Page 1A-4 90-8M0060785 DECEMBER 2011

Cylinder Block/Crankcase Specifications

Crankshaft main bearing journal A 55.993–56.001 mm (2.2044–2.2047 in.)

90-8M0060785 DECEMBER 2011 Page 1A-5

Cylinder Head Specifications

Camshaft to roller clearance Intake 0.0762 mm (0.003 in.)

Page 1A-6 90-8M0060785 DECEMBER 2011

Lubrication System Specifications

Power Trim Specifications

90-8M0060785 DECEMBER 2011 Page 1A-7

Gear Housing Specifications

Gear Housing Specifications

Power Steering Specifications

Page 1A-8 90-8M0060785 DECEMBER 2011

Hydraulic Steering Specifications

Diameter No. of Approx. Gross Boat Approx. Boat Propeller Part

90-8M0060785 DECEMBER 2011 Page 1A-9

Diameter No. of Approx. Gross Boat Approx. Boat Propeller Part

Page 1A-10 90-8M0060785 DECEMBER 2011

Diameter No. of Approx. Gross Boat Approx. Boat Propeller Part

90-8M0060785 DECEMBER 2011 Page 1A-11

Page 1A-12 90-8M0060785 DECEMBER 2011

90-8M0060785 DECEMBER 2011 Page 1B-1

Lubricants, Sealants, Adhesives

81 Anti-Seize Compound Spark plug threads 92-898101385

94 Anti-Corrosion Grease Propeller shaft 92-802867Q 1

Page 1B-2 90-8M0060785 DECEMBER 2011

EPA Emissions Regulations

Emission Certification Label

Inspection and Maintenance Schedule

Description Nm lb‑in. lb‑ft

After Each Use

90-8M0060785 DECEMBER 2011 Page 1B-3

Every 100 Hours of Use or Once Yearly, Whichever Occurs First

Description Nm lb‑in. lb‑ft

Tube Ref No. Description Where Used Part No.

Every 300 Hours of Use or Three Years

Before Periods of Storage

Flushing the Cooling System

1. These items should be serviced by an authorized dealer.

Page 1B-4 90-8M0060785 DECEMBER 2011

Top Cowl Removal and Installation

Cleaning Care for Top and Bottom Cowls

Cleaning and Waxing Procedure

90-8M0060785 DECEMBER 2011 Page 1B-5

3. Dry thoroughly with a soft clean cloth.

Cleaning Care for the Powerhead (Saltwater Use)

Tube Ref No. Description Where Used Part No.

Fuel Line Inspection

Low‑Pressure Fuel Filter

Page 1B-6 90-8M0060785 DECEMBER 2011

a - Fuel hose release tab

Corrosion Control Anode