150/150 Seapro/ 150 Pro Xs Fourstroke: Service Manual

150/150 SeaPro/150 Pro XS FourStroke
150/150 SeaPro/
150 Pro XS
S ERV IC E M A NUA L
FourStroke
S ERVI CE
MANUAL
1B905505 and Above

Serial Numbers
AUGUST 2020
90-8M0168224
www.mercurymarine.com.au www.mercurymarine.com www.brunswick-marine.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
© Mercury Marine. All rights reserved. 90-8M0168224 AUGUST 2020 S er i a l N u m b er s 1 B 9 0 5 5 0 5 a n d A b o v e

Printed in U.S.A.
Notice to Users of This Manual
Throughout this publication, safety alerts labeled WARNING and CAUTION (accompanied by the 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 these alerts 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.
! 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.
Additional alerts provide information that requires special attention:
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure.
IMPORTANT: Indicates 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 Mercury Marine Service Department to aid our dealers’ mechanics and
company service personnel when servicing the products described herein. 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 tools 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
results of each method. Therefore, anyone who uses a service procedure or tool that is not recommended by the manufacturer
must first completely satisfy himself that neither his nor the product's 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 or service these
products. We reserve the right to make changes to this manual without prior notification.
Refer to dealer service bulletins, operation and maintenance manuals, and installation manuals for other pertinent information
concerning the products described in this manual.
Precautions
While working on the product, keep in mind 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 workstands, or lowered to
the ground as soon as possible.
Page i © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

Replacement Parts
! WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with
federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system
components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and
tighten all components.
Use of parts other than the recommended service replacement parts will void the warranty on those parts that are damaged as
a result.
Cleanliness and Care of Product

A Mercury Marine power product is a combination of many machined, honed, polished, and lapped surfaces with tight
tolerances. When any product component is serviced, care and cleanliness are important. Proper cleaning and protection of
machined surfaces and friction areas is an implied 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.
Copyright and Trademark Information

© MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited.
Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, GO BOLDLY, K‑planes, Mariner, MerCathode,
MerCruiser, Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury
Racing, MotorGuide, OptiMax, Pro XS, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort,
Zeus, #1 On the Water and We're Driven to Win are registered trademarks of Brunswick Corporation. Mercury Product
Protection is a registered service mark of Brunswick Corporation. All other marks are the property of their respective owners.
90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine 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 - Accessory Wire Diagrams
Powerhead
4
5
D - Descriptive Fault List
E - Mercury Universal Fault Code Midsection
3 - Fuel System
A - Theory of Operation
B - Troubleshooting and Diagnostics
C - Service Procedures
Gear Housing
6
D - Emissions
4 - Powerhead
A - Cylinder Block/Crankcase
Control Linkage and Attachments
7
B - Cylinder Head
C - Lubrication
D - Cooling
Color Diagrams
8
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 S/N 2B172248 and Below
C - Left-Hand Rotation S/N 2B172249 and Above
D - Right-Hand Rotation (Pro XS)
7 - Control Linkage and Attachments
A - Throttle Linkage
B - Shift Linkage
C - Cowl Latch
8 - Color Diagrams
A - Color Diagrams
Page iii © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page iv
Master Specifications
1
Section 1A - Master Specifications A
Table of Contents
Master Specifications.........................................................1A-2 Power Trim Specifications.......................................... 1A-7
General Specifications................................................1A-2 Midsection Specifications........................................... 1A-7
Ignition Specifications................................................. 1A-3 Right‑Hand Gear Housing Specifications................... 1A-7
Charging and Starting Specifications..........................1A-3 Left‑Hand Gear Housing Specifications, S/N
Fuel System Specifications.........................................1A-4 2B172248 and Below.............................................. 1A-8
Cylinder Block/Crankcase Specifications................... 1A-5 Left‑Hand Gear Housing Specifications, S/N
Cylinder Head Specifications......................................1A-6 2B172249 and Above..............................................1A-8
Lubrication System Specifications.............................. 1A-7 Gear Housing Specifications (Pro XS 4.8 in.) ............1A-8
Cooling Specifications................................................ 1A-7 Gearcase Lubricant Capacity..................................... 1A-8
90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page 1A-1

General Specifications
Model Specifications
Kilowatts (horsepower) 110 kW (150 hp)
Number of cylinders 4
150 L 206 kg (455 lb)
Outboard weight 150 XL/CXL 213 kg (470 lb)
150 XL D2 215 kg (473 lb)
Displacement 3.0 liter (183 in.³)
Cylinder bore 101.609 mm (4.0 in.)
Stroke 92.00 mm (3.62 in.)
Idle 650 ± 50
Idle charge compensation* 650–800
Troll control limit (if equipped) 550–1000
RPM
150 WOT 5000–5800
150 Pro XS WOT 5200–6000
150 SeaPro WOT 4800–5300
Computer controlled multiport
Fuel system
electronic fuel injection
SmartCraft engine control module
Ignition system
(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
Regulated belt driven 55 A
Charging system
alternator
Exhaust system Through‑the‑propeller
Cooling system Water‑cooled ‑ thermostat
Lubrication system
Integrated dry sump 6.0 Liter (6.3 US qt)
Trim system
Maximum tilt range 73° (–6° to 67°)
Maximum trim range 20° (–6° to 14°)
* The idle charging compensation RPM may automatically increase up to 800 RPM to compensate for a low battery charge
condition. The increased idle RPM will charge the battery at a higher rate. Activating the troll control (optional accessory) will
override this low battery charge condition feature.
Page 1A-2 © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

Ignition Specifications
Idle 650 ± 50 RPM
Troll control limit (if equipped) 550–1000 RPM
150 5000–5800 RPM
WOT 150 Pro XS 5200–6000 RPM
150 SeaPro 4800–5300 RPM
Ignition type Digital inductive
Ignition timing at idle Approximately 2° BTDC; ECM controlled
Ignition timing at WOT ECM controlled
ECM overspeed limit 150 Activates at 5900 RPM
(forward and reverse) 150 Pro XS Activates at 6100 RPM
150 SeaPro Activates at 5400 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.

Fuel System Specifications

Automotive unleaded with a minimum pump posted octane rating
Type of fuel
of 87 (90 RON)
Approximate fuel pressure at idle 280–320 kPa (40.6–46.4 psi)
Approximate fuel pressure engine not running 335–375 kPa (48.6–54.4 psi)
Fuel filtration
Fuel inlet 20 microns
High‑pressure Design 1—20 microns, Design 2—46 microns
Amperage draw* 10 A ± 3 A
*Measurement performed at engine idle, fully primed fuel system (no air entrained) and fully charged battery (normal system
voltage).All fuel additives used in this engine

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 0.65–0.80 mm (0.0256–0.0315 in.)
Third (lower ring only) 0.25–0.76 mm (0.0098–0.0299 in.)

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.)
Intake 0.0762 mm (0.003 in.)
Camshaft to roller clearance (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°
Intake 0.38 ± 0.2 mm (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.)

Lubrication System Specifications

Engine capacity with filter replacement 6 liters (6.3 US qt)
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

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
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.)
Right‑Hand Gear Housing Specifications

Gear ratio (teeth) 150, 150 SeaPro 1.92:1 (13/25)
Gear housing capacity 830 ml (28.1 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 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)

Left‑Hand Gear Housing Specifications, S/N 2B172248 and Below

Left‑Hand Gear Housing Specifications S/N 2B172248 and below
Gear ratio 1.92:1 (13/25 teeth)
Reverse gear backlash N/A
Water pressure
At WOT 80–300 kPa (11.6–43.5 psi)
Left‑Hand Gear Housing Specifications, S/N 2B172249 and Above

Left‑Hand Gear Housing Specifications S/N 2B172249 and above
Water pressure
At WOT 80–300 kPa (11.6–43.5 psi)
Gear Housing Specifications (Pro XS 4.8 in.)

Description Specification
Gearcase capacity 970 ml (32.8 fl oz)
Front gear backlash 0.482–0.660 mm (0.019–0.026 in.)
Rear gear backlash 1.27–1.47 mm (0.050–0.058 in.)
Water pressure
At WOT 80–300 kPa (11.6–43.5 psi)
Gear housing pressure (without gear lubricant, 5 minutes without leakage) 103.4 kPa (15 psi)
Gearcase Lubricant Capacity

Gearcase Lubricant Capacity (approximate)
Right‑hand rotation gearcase 830 ml (28.1 fl oz)
Left‑hand rotation gearcase (S/N 2B172248 and below) 545 ml (18.4 fl oz)
Left‑hand rotation gearcase (S/N 2B172249 and above) 830 ml (28.1 fl oz)
SeaPro left and right‑hand rotation 830 ml (28.1 fl oz)
Pro XS 970 ml (32.8 fl oz)

Maintenance
1
Section 1B - Maintenance B
Table of Contents
General Specifications....................................................... 1B-2 Corrosion Control Anode................................................. 1B-10
Outboard Care................................................................... 1B-3 Propeller Replacement.................................................... 1B-10
Selecting Replacement Parts For Your Outboard...... 1B-3 Flo‑Torq II Propellers................................................ 1B-11
EPA Emissions Regulations.............................................. 1B-3 Flo‑Torq IV Propellers...............................................1B-12
Emission Certification Label....................................... 1B-3 Spark Plug Inspection and Replacement.........................1B-12
Owner Responsibility.................................................. 1B-3 Fuse Replacement...........................................................1B-13
Inspection and Maintenance Schedule.............................. 1B-4 Alternator Belt.................................................................. 1B-14
Before Each Use.........................................................1B-4 Alternator Drive Belt Inspection................................ 1B-14
After Each Use............................................................1B-4 Alternator Belt Failure Identification..........................1B-15
Every 100 Hours of Use or Once Yearly, Whichever Alternator Belt Replacement.....................................1B-16
Occurs First.............................................................1B-4 Lubrication Points............................................................ 1B-18
Every 300 Hours of Use or Three Years.....................1B-4 Checking Power Trim Fluid..............................................1B-19
Before Periods of Storage.......................................... 1B-5 Checking and Adding Engine Oil..................................... 1B-20
Maintenance Schedule Decal 150..................................... 1B-5 Changing Engine Oil ....................................................... 1B-21
Flushing the Cooling System............................................. 1B-7 Engine Oil Capacity.................................................. 1B-21
Top Cowl Removal and Installation................................... 1B-7 Oil Changing Procedure........................................... 1B-21
Removal......................................................................1B-7 Changing Oil Filter ................................................... 1B-21
Installation...................................................................1B-8 Oil Filling................................................................... 1B-22
Cleaning Care for Top and Bottom Cowls......................... 1B-8 Gearcase Lubrication.......................................................1B-22
Cleaning and Waxing Procedure................................ 1B-8 Gearcase Lubricant Recommendation..................... 1B-22
Cleaning Care for the Powerhead (Saltwater Use)............1B-8 Gearcase Lubricant Capacity................................... 1B-23
Battery Inspection ............................................................. 1B-8 Draining Gearcase....................................................1B-23
Fuel System....................................................................... 1B-9 Filling Gearcase........................................................1B-23
Fuel Line Inspection....................................................1B-9 Draining Gearcase—SeaPro Models........................1B-23
Low‑Pressure Fuel Filter.............................................1B-9 Filling Gearcase—SeaPro Models............................1B-24
90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page 1B-1

Maintenance
General Specifications
Model Specifications
Kilowatts (horsepower) 110 kW (150 hp)
150 L 206 kg (455 lb)
Outboard weight
150 XL/CXL 213 kg (470 lb)
Cylinder bore 101.609 mm (4.0 in.)
Stroke 92.00 mm (3.62 in.)
Idle 650 ± 50
Idle charge compensation* 650–800
Troll control limit (if equipped) 550–1000
RPM
150 WOT 5000–5800
150 Pro XS WOT 5200–6000
150 SeaPro WOT 4800–5300
Computer controlled multiport
Fuel system
electronic fuel injection
SmartCraft engine control module
Ignition system
(ECM) 70 digital inductive
Regulated belt driven 55 A
Charging system
alternator
Exhaust system Through‑the‑propeller
Cooling system Water‑cooled ‑ thermostat
Lubrication system
Integrated dry sump 6.0 Liter (6.3 US qt)
Trim system
Maximum tilt range 73° (–6° to 67°)
Maximum trim range 20° (–6° to 14°)
* The idle charging compensation RPM may automatically increase up to 800 RPM to compensate for a low battery charge
condition. The increased idle RPM will charge the battery at a higher rate. Activating the troll control (optional accessory) will
override this low battery charge condition feature.
Lubricant, Sealant, Adhesives

Tube Ref No. Description Where Used Part No.
Propeller shaft
Extreme Grease 8M0071842
Steering cable
25 Liquid Neoprene Fusible link wire connection 92- 25711 3
81 Anti-Seize Compound Spark plug threads 92-898101389

High Performance Gear
87 Gear housing 92-858064K01
Lubricant
Propeller shaft
95 2-4-C with PTFE 92-802859A 1
Steering cable
Power Trim and Steering
114 Power trim reservoir 92-858074K01
Fluid
Page 1B-2 © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

Maintenance

External metal surfaces of the powerhead and powerhead
120 Corrosion Guard 92-802878 55
components.
Special Tools
Leakage Tester Kit FT8950
Checks gear housing for leakage prior to filling with gear lubricant.
29497
Outboard Care
To keep the outboard in the best operating condition, perform the periodic inspections and maintenance listed in the
Inspection and Maintenance Schedule. Proper maintenance will ensure the safety of the operator, passengers, and retain
the outboard dependability.
Record maintenance performed in the Maintenance Log located in the owner's manual. Save all maintenance work orders and
receipts.
Selecting Replacement Parts For Your Outboard

We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants.
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- US EPA engine family name
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.

Maintenance
Inspection and Maintenance Schedule

Before Each Use
• Check the engine oil level. Refer to Checking and Adding Engine Oil.
• Check that 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, tighten
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 – 55.3
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 or polluted 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.
• If operating in saltwater, inspect the powerhead and powerhead components for salt buildup. Refer to Cleaning Care for
the Powerhead (Saltwater Use).
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.
• Replace the low‑pressure fuel filter. Refer to Fuel System.
• Check the outboard mounting fasteners that secure the outboard to the boat transom. Tighten the fasteners to the
specified torque. This item should be serviced by an authorized dealer.

• Check the corrosion control anodes. Check more frequently when used in saltwater. Refer to Corrosion Control Anode.
• Drain and replace gearcase lubricant. Refer to Gearcase Lubrication.
• Inspect the battery. Refer to Battery Inspection.
• Saltwater usage: Remove and inspect spark plugs for corrosion and replace spark plugs, as necessary. Apply a thin layer
of Anti‑Seize Compound only on the threads of the spark plug prior to installation. Refer to Spark Plug Inspection and
Replacement.

• Check the wiring and connectors.
• Check the tightness of bolts, nuts, and other fasteners.
• Check the cowl seals to ensure that the seals are intact and not damaged.
• Check the internal cowl sound reduction foam (if equipped) to ensure that the foam is intact and not damaged.
• Check that the intake silencer (if equipped) is in place.
• Check 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

• Replace the water pump impeller (more often if overheating occurs or reduced water pressure is noted). This item should
be serviced by an authorized dealer.

Maintenance
• Check the power trim fluid. Refer to Checking Power Trim Fluid.
• Replace the spark plugs after the first 300 hours or three years. After that, inspect the spark plugs every 300 hours or three
years. Replace spark plugs as needed. Refer to Spark Plug Inspection and Replacement.
• Visually inspect the thermostat for corrosion or a broken spring. Verify the thermostat closes completely at room
temperature. This item should be serviced by an authorized dealer.
• Lubricate the splines on the upper driveshaft. This item should be serviced by an authorized dealer.
• Replace the alternator drive belt. Refer to Alternator Drive Belt Inspection. This item should be serviced by an
authorized dealer.
Before Periods of Storage

• Refer to Storage.
Maintenance Schedule Decal 150
60074
150 EFI FourStroke

Maintenance
MAINTENANCE SCHEDULE
EVERY 100 HOURS EVERY 300 HOURS
OF USE OR OF USE OR
ONCE YEARLY THREE YEARS
REPLACE REPLACE
Engine Oil Accessory
and Filter Drive Belt
Gearcase
Lubricant Spark Plugs
Water Pump
INSPECT Impeller
Spark Plugs
Thermostat
Low Pressure
Fuel Filter
For Storage Preparation
Anodes
See Owner’s Manual
Specifications
In Saltwater: Engine Oil
Full Apply
Throttle Anti-Seize +120 +49
RPM: +100 +38
10W-30
+80 +27
5200-6000 +60 +16
Neutral +40 +4
+20 -7
Idle 0 -18
RPM:
F C
650
6.0 L (6.3 U.S. qt.)
67570
150 Pro XS
57668
150 FourStroke SeaPro
The following table shows the icons and a general description of the maintenance schedule decal that is located on the engine.
Icon Definition Icon Definition
Replace Inspect
58249 58250

Maintenance
Icon Definition Icon Definition
Engine oil and filter Gearcase lubricant

58251 58252
Spark plugs Thermostat

58253
58254
Low‑pressure fuel filter Anodes

58255 58256
Water pump impeller

58258
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.
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

Maintenance
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.
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.

Maintenance
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.
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.

Maintenance
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 toward 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.
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 activate the lanyard stop switch to prevent the
engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.

Maintenance
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.
5. Coat the propeller shaft with Extreme Grease or 2‑4‑C with PTFE.
47623

Extreme Grease Propeller shaft 8M0071842
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.

Maintenance
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 – 55.3
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 – 55.3
Spark Plug Inspection and Replacement

1. Pull the rubber boots off the spark plugs.
47660

Maintenance
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.

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.

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 verify
become frayed and the ribs are forces the belt to kink or twist while the alignment of the
removed. A noticeable noise may running, causing premature wear. pulley.
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
Replace the belt
material have broken off the belt. parallel to the cord line. Heat, age,
immediately.
When chunk‑out has occurred, a and stress are the primary
belt can fail at any moment. contributors.
40797

Maintenance
Appearance Description Cause Solution
Uneven rib wear

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

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

IMPORTANT: Ensure that the battery cables have been disconnected.
1. Install the alternator onto the cylinder block. Secure the alternator with an M10 x 60 screw and tighten to the specified initial
torque.
48140

Front alternator screw (M10 x 60) initial torque 7 62 –
2. Install the alternator belt so the letters and numbers on the belt are legible.
48141

Maintenance
3. Push the alternator toward 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
71399

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 fusible link wire connection to prevent corrosion and allow to dry.

Maintenance
9. Pull the insulator boot over the fusible link connection.
a - Insulator boot—fusible link

b - Alternator sense connector
b
48080

Nut securing fusible link to alternator 4.5 39.8 –

10. Connect the battery cables to the batteries.
Lubrication Points
1. Lubricate the following with Extreme Grease or 2‑4‑C with PTFE.

Extreme Grease Propeller shaft 8M0071842
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 2‑4‑C with PTFE or Extreme Grease.

95 2-4-C with PTFE Steering cable 92-802859A 1
Extreme Grease Steering cable 8M0071842

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

NOTE: This procedure is shown using the Design 1 power trim pump. The Design 2 power trim pump is similar.
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).

Maintenance

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

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: Ensure that any trapped oil drains back to the oil sump by tilting the outboard out/up past vertical for
approximately one minute.
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.
a a - Oil drain valve

b - Drain hose
c - Loosen 2‑1/2 turns maximum
2-12
b
c
48870
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.

Oil drain valve 15 132.7 –
IMPORTANT: Overtightening the oil drain valve can damage the oil sump.
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. Remove the old filter by turning the filter counterclockwise.
3. Allow oil in the trough to drain and remove the oil drain hose.

Maintenance
4. Clean any oil from the oil trough and install the plug.
a a- Loosen
b- Oil filter
c- Oil trough
d- Drain hose
b
c
d
47562
5. Clean the oil filter mounting base. Apply a film of clean oil to the filter gasket. Do not use grease. Install the new filter by
turning clockwise until the gasket contacts the base, then tighten 3/4 to 1 turn.
Oil Filling
1. Remove the oil fill cap and add approximately 6 Liter (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
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.
Gearcase Lubricant Recommendation

Mercury or Quicksilver High‑Performance Gear Lubricant.

Maintenance
Gearcase Lubricant Capacity

Gearcase Lubricant Capacity (approximate)
Right‑hand rotation gearcase 830 ml (28.1 fl oz)
Left‑hand rotation gearcase (S/N 2B172248 and below) 545 ml (18.4 fl oz)
Left‑hand rotation gearcase (S/N 2B172249 and above) 830 ml (28.1 fl oz)
SeaPro left and right‑hand rotation 830 ml (28.1 fl oz)
Pro XS 970 ml (32.8 fl oz)
Draining Gearcase
1. Place the outboard in a vertical operating position.
2. Remove the propeller. Refer to Propeller Replacement.
3. Place the drain pan below the outboard.
4. Remove the vent plug and fill/drain plug and drain lubricant.
a - Vent plug
b - Fill/drain plug
b
a
22692
Filling Gearcase
1. Place the outboard in a vertical operating position.
2. Remove the vent plug/sealing washer.
3. Remove the fill/drain plug. Place the lubricant tube into the fill hole and add the lubricant until it appears at the vent hole.
a - Vent hole
b - Fill hole
a
22693
IMPORTANT: Replace the sealing washers if damaged.

4. Stop adding the lubricant. Install the vent plug and sealing washer before removing the lubricant tube.
5. Remove the lubricant tube and install a cleaned fill/drain plug and sealing washer.
Draining Gearcase—SeaPro Models

All SeaPro FourStroke Outboards include a gearcase lubricant drain located at the front of the torpedo. Gearcase lubricant
changes can be completed while the outboard is tilted up.
NOTE: The front drain/fill plug has a magnet to collect debris. The plug must be cleaned, and any collected metal debris
removed before installation.
1. Place the outboard in the tilted up position.
2. Remove the upper vent plug.
3. Position a clean drain pan under the gear housing.

Maintenance
4. Remove the front drain/fill plug from the torpedo and drain the lubricant.
a b
62153
a - Upper vent plug

b - Front drain/fill plug
Filling Gearcase—SeaPro Models

NOTE: The gear housing should be pressure tested prior to filling with lubricant. Using Leakage Tester FT8950, the gear
housing should hold 103.4 kPa (15 psi) of pressure for 15 minutes without leakage. Failure to hold specified pressure indicates
worn or damaged sealing surfaces or improperly assembled gear housing. The cause of the leak must be corrected before
returning the gear housing assembly into service.
Gear Housing Test Pressure

Applied air pressure 103.4 kPa (15 psi)
Length of time 15 minutes

2. Remove the upper vent plug/sealing washer.
IMPORTANT: Never add lubricant to gear housing without first removing the vent plug.
3. Remove the front fill/drain plug from the torpedo. Place the lubricant tube into the fill hole.
4. Add gear lube until it is visible at the upper vent plug hole.
a a - Upper vent plug/hole

a b - Gearcase lubricant drain/fill hole
c - Front drain/fill plug
62154
5. Stop adding the lubricant. Install the upper vent plug and sealing washer before removing the lubricant tube.
6. Remove the lubricant tube and quickly install the cleaned fill/drain plug and sealing washer. Tighten the front drain/fill plug
and upper vent plug to the specified torque.
IMPORTANT: Do not lose more than 30 cc (1 fl oz) of gear lubricant while installing the front fill/drain plug.

Maintenance

High Performance Gear
Lubricant

Upper vent plug/sealing washer 11.3 100 –
Front fill/drain plug 11.3 100 –

Maintenance
Notes:

General Information
1
Section 1C - General Information C
Table of Contents
Recording Serial Number.................................................. 1C-2 Warning System.............................................................. 1C-12
Powerhead Components................................................... 1C-3 Warning Horn Signals...............................................1C-12
Front View.................................................................. 1C-3 Engine Guardian System..........................................1C-13
Port View.................................................................... 1C-4 Overspeed Rev Limit................................................ 1C-13
Aft View...................................................................... 1C-5 SmartCraft Product...................................................1C-13
Starboard View........................................................... 1C-6 Power Trim and Tilt..........................................................1C-13
Top View.....................................................................1C-7 Power Trim And Tilt.................................................. 1C-13
Accessory Views—Standard on SeaPro Models........1C-8 Power Trim Operation.............................................. 1C-14
Conditions Affecting Performance..................................... 1C-8 Tilting Operation....................................................... 1C-14
Weather...................................................................... 1C-8 Manual Tilting........................................................... 1C-14
Weight Distribution (Passengers and Gear) Inside the Auxiliary Tilt Switch...................................................1C-15
Boat.........................................................................1C-9 Shallow Water Operation..........................................1C-15
Bottom of Boat ...........................................................1C-9 Cylinder Leakage Testing................................................ 1C-15
Water Absorption........................................................1C-9 Analysis.................................................................... 1C-15
Cavitation....................................................................1C-9 Painting Procedures........................................................ 1C-16
Ventilation...................................................................1C-9 Propellers................................................................. 1C-16
Detonation.................................................................. 1C-9 Gearcase and Lower Housing.................................. 1C-16
Following Complete Engine Submersion ........................1C-10 Cowl..........................................................................1C-17
Engine Submerged While Running (Special Cleaning and Maintenance.............................................. 1C-17
Instructions).......................................................... 1C-10 General Cleaning Instruction.................................... 1C-17
Freshwater Submersion (Special Instructions).........1C-10 Shipping of Hazardous Material (HazMat) and Engine/
Saltwater Submersion (Special Instructions)............1C-10 Components Containing Hazardous Material.............. 1C-18
Fuel and Oil..................................................................... 1C-10 Outboard Service Bulletin 2008‑07...........................1C-18
Fuel Requirements................................................... 1C-10 Overview of Regulations...........................................1C-18
Filling Fuel Tank....................................................... 1C-11 Overview of Training Requirements......................... 1C-18
Engine Oil Recommendations—Standard and Pro XS Shipping of Complete Engines and Major Assemblies
Models.................................................................. 1C-11 .............................................................................. 1C-18
Engine Oil Recommendations—SeaPro Models......1C-12 More Information on Hazardous Material................. 1C-18
90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page 1C-1

General Information
Special Tools
Cylinder Leakage Tester Snap‑On EEPV309A
Aids in checking cylinder leakdown.
11604
Recording Serial Number

It is important to record this number for future reference. The serial number is located on the outboard, as shown.
Model Number
b XXXXXXX a - Serial number
Serial Number b - Model designation
a XXXXXXX
c - Year manufactured
XXXXXX
HP XXX KW XXX
LB XXX KG XXX
Mercury Marine
Brunswick Corp.
Fond du Lac, WI 54935
Assembled in the USA
from US and foreign
components
XX
c 54204
Page 1C-2 © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

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

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

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

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

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

General Information
Accessory Views—Standard on SeaPro Models
SC1000 tachometer gauge
1- Water‑separating fuel
filter
2- Filter base with 11/16
in.‑16 filter fitting
3- 3/8 in.‑18 NPTF fuel
line fitting (2)
4- 3/8 in.‑18 NPTF plug
(2)
3 4 5 5- Hose clamp (2)
1 2 60044
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). Nothing will regain this speed for the
boater but cooler, dry weather.
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 engine's RPM. An engine with too large of 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.

General Information
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
• 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

General Information
• 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.
Freshwater Submersion (Special Instructions)

1. Recover the engine as quickly as possible.
2. Place the 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 the 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 the integrated air fuel module (IAFM) and drain the water from the IAFM assembly.
7. Remove and clean the fuel rail, fuel supply module, idle air control, throttle body, and fuel pump assembly.
8. Pour approximately one teaspoon of engine oil into each spark plug opening. Rotate the flywheel to distribute the oil in the
cylinders.
9. Change the engine oil. Run the outboard for a short time and check for the presence of water in the oil. If water is present,
the oil will appear milky. Drain and replace the oil.
10. Dry all wiring and electrical components using compressed air.
11. Disassemble the engine starter motor and dry all the internal parts with compressed air. Be careful not to lose the brush
springs.
12. Reinstall the spark plugs.
13. Attempt to start the engine, using a fresh fuel source. If the engine starts, it should be run for at least one hour to eliminate
any water in the engine. If water is present, the oil will appear milky. Drain and replace the oil as previously mentioned.
NOTE: The fuel system is closed to ambient air at all times when the engine is not running.
14. 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.
Fuel and Oil

Fuel Requirements
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 will not be covered under the limited warranty.
Fuel Ratings
Mercury outboard engines will operate satisfactorily with any major brand of unleaded gasoline that meets the following
specifications:
USA and Canada ‑ A posted pump octane rating of 87 (R+M)/2, minimum, for most models. Premium gasoline 91 (R+M)/2
octane is also acceptable for most models. Do not use leaded gasoline.
Outside USA and Canada ‑ A posted pump octane rating of 91 RON, minimum, for most models. Premium gasoline (95 RON)
is also acceptable for all models. Do not use leaded gasoline.

General Information
Using Reformulated (Oxygenated) Gasoline (USA Only)

Reformulated gasoline is required in certain areas of the USA and is acceptable for use in your Mercury Marine engine. The
only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).
Gasoline Containing Alcohol

Bu16 Butanol Fuel Blends
Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury Marine fuel rating requirements are an acceptable
substitute for unleaded gasoline. Contact your boat manufacturer for specific recommendations on your boat's fuel system
components (fuel tanks, fuel lines, and fittings).
Methanol and Ethanol Fuel Blends
IMPORTANT: The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol (methanol or
ethanol) content in the gasoline. Your boat's fuel system may not be capable of withstanding the same percentage of alcohol.
Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines,
and fittings).
Be aware that gasoline containing methanol or ethanol may cause increased:
• Corrosion of metal parts
• Deterioration of rubber or plastic parts
• Fuel permeation through the rubber fuel lines
• Likelihood of phase separation (water and alcohol separating from the gasoline in the fuel tank)
! 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.
IMPORTANT: If you use gasoline that contains or might contain methanol or ethanol, you must increase the frequency of
inspection for leaks and abnormalities.
IMPORTANT: When operating a Mercury Marine engine on gasoline containing methanol or ethanol, do not store the gasoline
in the fuel tank for long periods. Cars normally consume these blended fuels before they can absorb enough moisture to cause
trouble; boats often sit idle long enough for phase separation to take place. Internal corrosion may occur 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 the fuel tanks outdoors away from heat, sparks, and open flames.
Remove the portable fuel tanks from the boat to fill them.
Always stop the engine before filling the tanks.
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—Standard and Pro XS Models

Mercury or Quicksilver NMMA FC‑W or NMMA FC‑W catalyst compatible certified SAE 10W‑30 Marine 4‑Stroke Engine Oil is
recommended for general all‑temperature use. As an optional choice, Mercury or Quicksilver SAE 25W‑40 Mineral Marine
4‑Stroke Engine Oil or SAE 25W‑40 Synthetic Blend Marine 4‑Stroke engine oil may be used. If the recommended Mercury or
Quicksilver NMMA FC‑W certified oils are not available, a major outboard manufacturer's brand of NMMA FC‑W certified
4‑Stroke outboard oil of similar viscosity may be used.

General Information
IMPORTANT: The use of nondetergent oils, multiviscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a
major brand NMMA FC‑W certified oil), full synthetic oils, low quality oils, or oils that contain solid additives are not
recommended.
6.0 L (6.3 US qt)
60104
Engine Oil Recommendations—SeaPro Models

Mercury or Quicksilver NMMA FC‑W or NMMA FC‑W catalyst compatible certified SAE 25W‑40 Mineral Marine 4‑Stroke
Engine Oil or SAE 25W‑40 Synthetic Blend Marine 4‑Stroke Engine Oil is recommended for general all‑temperature use. As an
optional choice, Mercury or Quicksilver or SAE 10W‑30 Marine 4‑Stroke Engine Oil may be used when temperatures are 0 °C
(32 °F) or less. If the recommended Mercury or Quicksilver NMMA FC‑W certified oils are not available, a major outboard
manufacturer's brand of NMMA FC‑W certified 4‑Stroke outboard oil of similar viscosity may be used.
IMPORTANT: The use of nondetergent oils, multiviscosity oils (other than Mercury or Quicksilver NMMA FC‑W certified oil or a
major brand NMMA FC‑W certified oil), full synthetic oils, low quality oils, or oils that contain solid additives are not
recommended.
10W-30
25W-40
6.0 L (6.3 US qt)
60105
Warning System
Warning Horn Signals
When the key switch is turned to the ON position, the horn will turn on for a moment as a test to indicate the horn is working.
There are two types of warning horns to alert the operator of an active problem within the engine’s operating system.
1. Continuous six second beep: Indicates a critical engine condition. Depending on the condition, the Engine Guardian
system may engage and protect the engine by limiting power. You should return to port immediately and contact your
servicing dealer.
2. Intermittent short beeps for six seconds: Indicates a noncritical engine condition. This condition does not require
immediate attention. You may continue using your boat, however, depending on the nature of the problem, the engine’s
power may be limited by the Engine Guardian system (see Engine Guardian System following) to protect the engine. You
should contact your servicing dealer at your earliest convenience.
It is important to note that in either of the above scenarios, the horn will only sound one time. If you key the engine off and
restart it, the horn will sound again, one time, if the fault is still present. For visual display of the specific engine functions and
additional engine data, refer to SmartCraft Product information, following.
A few of the noncritical conditions indicated by the intermittent short beeps for six seconds can be corrected by the operator.
These operator correctable conditions are as follows:

General Information
• Water in the engine mounted fuel filter. See the maintenance instructions provided with the optional water‑separating fuel
filter kit.
• Cooling system (water pressure or engine temperature) problem. Stop the engine and check the water intake holes in the
lower unit for obstruction.
• Low engine oil level. Refer to Checking and Adding Engine Oil.
Engine Guardian System

The Engine Guardian system monitors the critical sensors on the engine for any early indications of problems. Engine Guardian
is functional whenever your engine is operating, so you never have to be concerned about whether or not you are protected.
The system will respond to a problem by sounding the warning horn for six seconds and/or reducing engine power in order to
provide engine protection.
If Engine Guardian has been activated, reduce the engine speed. The problem will need to be identified and corrected. The
system must be reset before the engine will operate at higher speeds. Moving the throttle lever back to the idle position will
reset the Engine Guardian system. If the Engine Guardian system has determined the reset has not corrected the problem,
Engine Guardian will remain activated, limiting the throttle. The problem must be identified and corrected before Engine
Guardian will allow the engine to reach a normal operating RPM.
Overspeed Rev Limit

The overspeed rev limit is set at an RPM greater than the operating range. In the event that the engine is operated at an RPM
greater than or equal to the overspeed limit, the PCM does not allow the engine to maintain the power requested by the
operator. Refer to Section 1A ‑ Master Specifications to determine this engine’s RPM limit.
Upon reaching the beginning of the rev limit, Engine Guardian will cut‑out the ignition to specific cylinders. If the operator does
not reduce engine speed, Engine Guardian will cut‑out the ignition to all the cylinders. There is no audible warning while Engine
Guardian overspeed limit is active.
To reset the Engine Guardian protection:
1. Completely reduce the throttle for three seconds.
2. Engage the throttle. If the engine does not respond, repeat step one.
SmartCraft Product
A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument
package will display are engine RPM, coolant temperature, oil pressure, water pressure, battery voltage, fuel consumption, and
engine operating hours.
The SmartCraft instrument package will also aid in Engine Guardian diagnostics. The SmartCraft instrument package will
display critical engine alarm data and potential problems.
Power Trim and Tilt

The outboard has a trim/tilt control called power trim. This enables the operator to easily adjust the position of the outboard by
pressing the trim switch. Moving the outboard in closer to the boat transom is called trimming in or down. Moving the outboard
further away from the boat transom is called trimming out or up. The term trim generally refers to the adjustment of the
outboard within the first 20° range of travel. This is the range used while operating the boat on plane. The term tilt is generally
used when referring to adjusting the outboard further up out of the water. With the engine turned off and ignition switch turned
on, the outboard can be tilted out of the water. At low idle speed, the outboard can also be tilted up past the trim range to
permit, for example, shallow water operation.
a - Trim switch
b - Tilt range
a UP
DN c - Trim range
b
c 58238

General Information
Power Trim Operation

With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of
the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an
improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some
potential control hazards.
The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque
results from the outboard being trimmed so the propeller shaft is not parallel to the water surface.
! WARNING
Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss
of boat control. Maintain control of the boat if trimming beyond a neutral steering condition.
Consider the following lists carefully.

1. Trimming in or down can:
• Lower the bow
• Result in quicker planing off, especially with a heavy load or a stern heavy boat
• Generally improve the ride in choppy water
• Increase steering torque or pull to the right (with the normal right‑hand rotation propeller)
• In excess, can lower the bow of some boats to a point where they begin to plow with their bow in the water while on
plane. This can result in an unexpected turn in either direction (called bow steering or oversteering) if any turn is
attempted, or if a significant wave is encountered.
2. Trimming out or up can:
• Lift the bow higher out of the water
• Generally increase top speed
• Increase clearance over submerged objects or a shallow bottom
• Increase steering torque or pull to the left at a normal installation height (with the normal right‑hand rotation propeller)
• In excess, can cause boat porpoising (bouncing) or propeller ventilation
• Cause engine overheating if any cooling water intake holes are above the waterline
Tilting Operation
To tilt outboard, shut off the engine and press the trim/tilt switch or auxiliary tilt switch to the up position. The outboard will tilt up
until the switch is released or it reaches its maximum tilt position.
1. Engage the tilt support lever by rotating the knob to bring the support lever upward.
2. Lower the outboard to rest on the tilt support lever.
3. Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever down. Lower the
outboard.
a - Tilt support lever

b - Knob
a
b
47705
Manual Tilting
If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.
NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up
during reverse operation.

General Information
Turn out the manual tilt release valve three turns counterclockwise. This allows manual tilting of the outboard. Tilt the outboard
to the desired position and tighten the manual tilt release valve.
47663
Auxiliary Tilt Switch

This switch can be used to tilt the outboard up or down using the power trim system.
a - Auxiliary tilt switch

a
47704
Shallow Water Operation

When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom.
1. Reduce the engine speed below 2000 RPM.
2. Tilt the outboard up. Make sure all the water intake holes stay submerged at all times.
3. Operate the engine at slow speed only. If engine speed exceeds 2000 RPM, the outboard will automatically return down to
the maximum trim range.
Cylinder Leakage Testing

Cylinder Firing Order
1‑3‑4‑2
NOTE: Cylinder leakage 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. Remove all spark plugs.

2. Rotate the engine clockwise until cylinder #1 is at its compression stroke.
3. Complete the cylinder leak down test on the #1 spark plug hole. Refer to the manufacturer's tester instructions for proper
testing procedures.
4. After testing cylinder #1, install a dial indicator on the next firing order sequence cylinder.
5. Rotate the flywheel so the piston is at TDC.
6. Complete the cylinder leak down test.
7. Proceed with the succeeding firing order cylinder TDC and complete the cylinder leak down test.
8. Complete the procedure in sequence on the remaining cylinders.
Analysis
Due to standard engine tolerances and engine wear, no cylinder will maintain 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.

General Information
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 eyewear, clothing, and respirators.
Propellers
1. Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch‑Brite disc or belts.
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.
Gearcase and Lower Housing

! WARNING
Some cleaners and solvents are flammable. Improper use can result in serious injury or death from fire or explosion. Do not
use flammable cleaners on energized equipment, use in a well‑ventilated area, and keep away from open flames or sources
of ignition.
! WARNING
1. Clean the component to remove all oils, wax, grease, salts, and other marine build‑up with an appropriate marine cleaner.
Wipe the part with a solvent type wax remover, grease remover, or naphtha.
2. If this is a spot repair:
a. Sand the affected area with 180 or 220 grit to remove blisters and coarse pitting, if present.
b. Finish and feather into the surrounding paint with 320 grit either by hand or using dual‑action (DA) equipment. The
original primer should not be sanded through, if it can be avoided.
c. Scuff the entire component with a medium (maroon) Scotch‑Brite™ pad by hand.
3. If refinishing the entire component:
• Media blasting using either a plastic type or soda type media is allowable, provided proper precautions are taken to
prevent grit from entering any mechanisms.
• Complete disassembly and masking prior to media blasting is suggested, with glass media being acceptable in this
case.
4. Treat areas of bare aluminum with Alumiprep® 33, PPG DX‑533, or Metalprep 79. Rinse the area with clean water and
blow dry with clean compressed air.
5. When they are dry, treat the bare aluminum areas with Alodine® 1201™ or PPG DX‑503. Rinse again with clean water and
blow dry with clean compressed air. Masking, if needed, is to be done after this final rinse process, paying special attention
to the masking of anode and ground contact areas.
6. Complete a final wipe with a wax and grease remover or naphtha. Lightly remove dust with a tack rag.
7. Prime the bare aluminum areas with Stits EP‑420 (green) epoxy primer, mixed with Stits EP‑430 catalyst and Stits E‑500
reducer, per the manufacturer's mixing and application directions. PTI PT‑573 or Randolph Rand‑O‑Plate are acceptable
substitutes. Apply two medium wet coats, allowing 20 minutes between. If the topcoat color is Verado Silver, PPG Omni™
MP170 gray epoxy should be applied as a second (intermediate) primer for color match and scratch hiding on gearcases.

General Information
8. After it has cured for 24 hours, the primer may be scuffed lightly with a medium (maroon) Scotch‑Brite™ pad to feather the
edge of the spray into surrounding paint and to promote adhesion. Do not penetrate the primer. Wait no more than four
days before topcoating.
9. Topcoat with Stits Aerothane color code 215 for Mercury Phantom Black. Use Stits Catalyst U‑865 and UE‑820 Urethane
Reducer per manufacturer's mixing and application directions. PPG Omni™ MTK9300 is an acceptable substitute. Apply
two medium wet coats, allowing 15 minutes between. Allow to cure for 24 hours before handling.
NOTE: Other PPG topcoat colors are: DU34334 Mariner Silver, DU35466 Force Charcoal, and DU33414M Sea Ray White.
Use PPG DU5 catalyst and reduce per manufacturer's current technical information.
Cowl
! WARNING
Some cleaners and solvents are flammable. Improper use can result in serious injury or death from fire or explosion. Do not
use flammable cleaners on energized equipment, use in a well‑ventilated area, and keep away from open flames or sources
of ignition.
! WARNING
1. Wash and degrease the cowl with a water‑based cleaning solution. Simple Green® Aircraft & Precision Cleaner or Stewart
Systems EkoClean are suggested at a 10:1 mix ratio with clean water. Rinse with clean water.
2. Use an orbital dual‑action (DA) sander at low speed with an 80–100 grit disc to sand around any damaged areas. Low
speed is used to prevent melting of the cowl substrate and causing adhesion issues. Wipe with the same cleaner used to
wash the cowl, followed by a clean water wipe. Blow dry with compressed air.
3. Apply two light coats of Klean‑Strip® Bulldog® Adhesion Promoter to areas that were sanded to the base cowl material.
Omni™ MP178 Plastic Primer or equivalent is a suitable alternative.
4. Repair dings and scratches with Evercoat Poly‑Flex™ following manufacturer instructions. An equivalent filler designed for
flexible automotive components may be substituted. Sand to contour with a 180 grit disc, using an orbital DA sander, and
finish with a 320 grit disc to feather into the surrounding paint. If the entire cowl is to be refinished, scuff all surfaces with
either 320 grit or a maroon Scotch‑Brite™ pad, feathering in all minor chips and scratches.
5. Wipe down the cowl with the same cleaner used to wash and degrease the cowl, followed by a water wipe. Blow dry with
clean compressed air.
6. Prime all areas to be painted with Omni™ MP281 or MP282, mixing and using per manufacturer instructions. For top
quality cowl work, complete refinishing is suggested in place of spot repairs. If the topcoat color is white, PPG Omni™
MP170 gray epoxy should be applied as a second (intermediate) primer for color match and scratch hiding on cowls.
7. Lightly sand the primer with 320 grit using an orbital DA sander or by hand to a uniform surface. Wipe down and blow dry
as in previous steps. If there are no imperfections, a maroon Scotch‑Brite™ pad may be used instead.
8. Base coat with either Omni™ MBC9300 (Phantom Black), Delfleet® 938661 (Warm Fusion White), Delfleet® 938662 (Cold
Fusion White), PPG DU34334 (Mariner Silver), PPG DU35466 (Force Charcoal) using the manufacturer's mixing and use
guideline.
9. Topcoat with PPG Omni™ MC161 clear or equivalent, using the manufacturer's mixing and use guidelines. Use two full
wet coats of a high quality clear coat for long term durability.
10. If a top quality finish is required, or if errors in the clear coat need to be corrected, cut and buff the clear coat using a
reputable automotive‑type system, appropriate for the clear coat material.
11. Follow paint manufacturer's guidelines for cure times before machine finishing, waxing, or applying decals.
Cleaning and Maintenance

IMPORTANT: Never use petroleum products or strong household cleaning chemicals to clean the outside surface of the cowls.
Using petroleum products or strong household cleaning chemicals will cause damage to the decal and may damage the cowl.
IMPORTANT: Pressure wash and scrub brush with caution. Always use a wide spray pattern, low‑pressure, and an angle less
than 60° to the surface when using a pressure washer. Low angle water streams can lift the decal from the surface.
General Cleaning Instruction

• Rinse the surface well with lukewarm water to remove dirt.
• Use a soft cloth or sponge to gently wash the surface with a mild dishwashing soap with lukewarm water.
• Do not scrub, use a brush, or a squeegee.

General Information
• Rinse the surface thoroughly.

• Use a clean, soft, lint‑free cloth to dry and prevent water spotting.
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:
ShipMate Inc.
Telephone + 1 (310) 370‑3600
Fax + 1 (310) 370‑5700

General Information
ShipMate Inc.
E‑mail shipmate@shipmate.com

General Information
Notes:

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-3 ................................................................................ 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-4 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 Quick‑Disconnect Fuel Hose Fitting......................... 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
90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page 1D-1

Lubricants, Sealants, Adhesives

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
Fuel Pressure Gauge Kit 91‑881833A03
Tests the fuel pump pressure; can be used to relieve fuel pressure.
2807
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
Page 1D-2 © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

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.
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.
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") and self‑locking nylon insert locknuts ("c" and "d"). 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 (849838)

b b- Flat washers
c- Nylon insert locknut (8M0042636)
c d- Nylon insert locknut (8M0042636)
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 the steering link rod to the steering cable with two flat washers and a nylon insert locknut. Tighten the locknut until it
seats, then back the nut off 1/4 turn.
Assemble the steering link rod to the engine with a special washer head bolt and locknut. First torque the special washer head
bolt, then tighten the locknut to the specified torque.
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

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
8M0149747 Outboard mounting bolt 1/2‑20 x 4.50 in. long (2.25 in. thread)
826711 17 Nylon insert locknut 1/2‑20
28421 Flat washer 1‑1/2 in. diameter
54012 Flat washer 7/8 in. diameter
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 (55.3 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

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 g/m²/24 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) requires 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:
• 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 46453
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 Fuel Pressure Gauge

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; contains an antisiphon 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.
a a - Fuel pressure gauge purge valve

b - Schrader valve
c - Purge hose to appropriate container
58370
5. Open the fuel pressure gauge purge valve and turn the ignition key ON. The fuel pumps will run for approximately three to
five seconds.
6. Turn the ignition key OFF and then ON. The fuel pumps will run for approximately three to 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.
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 a 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 three to 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. After 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 Fuel Pressure Gauge 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.

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 53.1 –

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

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
Quick‑Disconnect Fuel Hose Fitting

! 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: The fuel line quick‑disconnect fuel hose fitting is not equipped with a check valve. Fuel will be present at the
connection and may drain from the hose when disconnected. Ensure there is a suitable container ready when disconnecting
the fuel line from the engine. Follow all fuel handling safety precautions. Wipe up spilled fuel and dispose of according to local
laws and regulation.
53883
Quick-disconnect fuel hose fitting
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.

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.

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.

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

Notes:

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
90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page 1E-1

Storage

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
124 Quickstor Fuel Stabilizer Fuel tank 92-8M0047932
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 NMMA®/GPP™ certified Quickstor Fuel 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 NMMA®/GPP™ certified Quickstor Fuel 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.

124 Quickstor Fuel Stabilizer Fuel tank 92-8M0047932
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 © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

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. Refer to Section 1B ‑ Gearcase Lubrication.
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 charging.
• Remove the battery from the boat and check water level. Charge if necessary.
• Store the battery in a cool, dry place.
• Periodically check the water level and charge 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.

Storage
Notes:

Ignition
Electrical
Section 2A - Ignition
Table of Contents 2
A
Ignition Specifications........................................................ 2A-2 Cylinder Block Coolant Temperature Sensor
Ignition Components.......................................................... 2A-4 Installation............................................................. 2A-26
Electrical Components....................................................... 2A-6 Manifold Absolute Pressure (MAP) Sensor..................... 2A-27
Troubleshooting Guide.......................................................2A-8 Manifold Absolute Pressure (MAP) Sensor Test...... 2A-27
Flywheel...........................................................................2A-10 Manifold Absolute Pressure (MAP) Sensor Removal
Engine Harness Connector..............................................2A-10 .............................................................................. 2A-28
Engine Control Module (ECM)......................................... 2A-10 Manifold Absolute Pressure (MAP) Sensor Installation
Engine Control Module Removal.............................. 2A-11 .............................................................................. 2A-28
Engine Control Module Installation........................... 2A-11 Idle Air Control (IAC)........................................................2A-29
Wire Color Code Abbreviations........................................2A-12 Idle Air Control (IAC) Testing....................................2A-29
Main Power Relay (MPR)................................................ 2A-12 IAC Removal.............................................................2A-30
Main Power Relay ....................................................2A-12 IAC Inspection and Installation................................. 2A-31
Main Power Relay Test.............................................2A-12 Manifold Air Temperature (MAT) Sensor ........................ 2A-32
Ignition Coil...................................................................... 2A-18 Manifold Air Temperature Sensor Test.....................2A-32
Ignition Coils............................................................. 2A-18 Manifold Air Temperature Sensor Removal..............2A-33
Ignition Coil Resistance Test.................................... 2A-19 Manifold Air Temperature Sensor Installation...........2A-34
Spark Plug Wire Resistance Test.................................... 2A-20 Shift Position Sensor........................................................2A-34
Crankshaft Position Sensor (CPS)...................................2A-20 Shift Position Sensor Test........................................ 2A-34
Crankshaft Position Sensor Test.............................. 2A-20 Shift Position Sensor Removal................................. 2A-35
Crankshaft Position Sensor Removal....................... 2A-21 Shift Position Sensor Installation.............................. 2A-36
Crankshaft Position Sensor Installation.................... 2A-22 Oil Pressure Sensor.........................................................2A-37
Throttle Position Sensor (TPS)........................................ 2A-23 Oil Pressure Sensor Test..........................................2A-37
Throttle Position Sensor Test................................... 2A-23 Oil Pressure Sensor Removal.................................. 2A-38
Cylinder Block Coolant Temperature Sensor...................2A-24 Oil Pressure Sensor Installation............................... 2A-39
Cylinder Block Coolant Temperature Sensor Test... 2A-24
Cylinder Block Coolant Temperature Sensor Removal
.............................................................................. 2A-25

Ignition
Idle 650 ± 50 RPM
Troll control limit (if equipped) 550–1000 RPM
150 5000–5800 RPM
WOT 150 Pro XS 5200–6000 RPM
150 SeaPro 4800–5300 RPM
Ignition type Digital inductive
Ignition timing at idle Approximately 2° BTDC; ECM controlled
Ignition timing at WOT ECM controlled
ECM overspeed limit 150 Activates at 5900 RPM
(forward and reverse) 150 Pro XS Activates at 6100 RPM
150 SeaPro Activates at 5400 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 Tool Kit 8M0153916
Interfaces CDS G3 software to SmartCraft network.

NOTE: This kit includes download instructions and a license key.
60575
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

Ignition
Notes:

Ignition
Ignition Components
1
2 3
48367

Ignition
Ignition Components
Torque
Ref. No. Qty. Description Nm lb‑in. lb‑ft
1 2 Dual output ignition coil
2 4 Screw (M6 x 30) 10.2 90 –
3 1 Spark plug set
4 4 Spark plug

Ignition
Electrical Components
21
20
1
14
12 11 3
1
8
9
6 7 15 21 10 8
5 13 7
6
5
16 22
8
17 18 7
23 8 6
19 7 5
6
5
48365

Ignition
Electrical Components
Torque
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
22 1 Maintenance schedule decal, SeaPro
23 1 Maintenance schedule decal

Ignition
Troubleshooting Guide
Spark Gap Tester 91‑850439T 1
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 five
1.1 No fuel
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 harness
1.7 Spark from one coil only
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.
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.
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.

Ignition
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
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.

Ignition
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.
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.

Ignition
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.
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 –

Ignition
Wire Color Code Abbreviations

Wire Color Abbreviations
BLK Black BLU Blue
BRN Brown GRA Gray
GRN Green ORN Orange
PNK Pink PPL Purple
RED Red TAN Tan
WHT White YEL Yellow
LT Light DK 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.

Ignition
f
d
c i
e
b h
PPL
PPL
g
18 34 51
1
67
a
68
PPL
PPL/WHT
PPL
69
70
33 50 66
17
j
k PPL
PPL
PPL
48843
a- ECM connector
b- Main power relay
c- 15‑amp fuse
d- ECM ground
e- Starter
f- Power stud
g- Battery ground (engine)
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.

Ignition
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.

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.

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.

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.

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.
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.
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.

Ignition
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
32
33
69
70
17 33 50 66
48926
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
Ignition Coil Resistance Test (Ω)

Between coil towers 7200–8800
Between pin A and B 0.3–0.5

Ignition
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
• 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.

Ignition
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.
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.

Ignition
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.

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.
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

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.

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.

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
48980
17 33 50 66
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.

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 –

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 signal 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.
54933
Manifold Absolute Pressure (MAP) 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.

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 a resistance check between MAP sensor pins A, B, and C.
PPL/YEL
c a- Pin A (black/orange)
C
YEL
b b- Pin B (yellow)
B
a
BLK/ORN
A
c- Pin C (purple/yellow)
d- MAP sensor
d 61259
Meter Test Leads Reading

Meter Scale
Red Black At 21 °C (70 °F)
A B Auto 4.28 kΩ ± 30%
A C Auto 1.93 kΩ ± 30%
B A Auto 4.29 kΩ ± 30%
B C Auto 6.48 kΩ ± 30%
C A Auto 1.93 kΩ ± 30%
C B Auto 6.8 kΩ ± 30%

Ignition
5. If the resistance check of the MAP sensor indicates that the MAP sensor is serviceable, perform a resistance check on the
wiring between the MAP sensor connector and the ECM connector.
failures, the most likely failure would be at the splice point, at the connector, or between the connector and the splice point.
a
1 18 34 51
67
68
b
69
70
66 48979
17 33 50
a - ECM connector
b - MAP sensor
Meter Test Leads

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

1. Disconnect the engine harness from the MAP sensor.
2. Remove the screw securing the MAP sensor retaining bracket.
3. Pull the MAP sensor from the throttle body.
Shown with the intake manifold removed

a a - Engine harness
b - MAP sensor
c - Throttle body
d - Retaining bracket
e - Screw
e
d
b
c
54934
Manifold Absolute Pressure (MAP) Sensor Installation

1. Push the MAP sensor into the intake manifold opening.
2. Install the MAP sensor retaining bracket into the intake throttle body.
3. Secure the retaining bracket with a screw. Tighten the screw to the specified torque.

Ignition
4. Connect the engine harness to the MAP sensor.
a- Engine harness
a b- MAP sensor
c- Throttle body
d- Retaining bracket
e- Screw
e
d
b
c
54934

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.
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.
1. Disconnect the engine harness from the IAC.

2. Disconnect the engine harness connector from the ECM.

Ignition
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
WHT/LT BLU
RED/BLU
1 18 34 51 a B A
67
68 3 WHT/LT BLU
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
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.

Ignition
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.
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 –

Ignition
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.

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.
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

Ignition
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
1 18 34 51 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.
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

Ignition
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.
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.
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.

Ignition
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.
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

Ignition
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 toward 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 –

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.
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
Meter Test Leads Reading (Ω)

Meter Scale
A B Auto 112.0 kΩ ± 30%
A C Auto 260.0 kΩ ± 30%

Ignition
Meter Test Leads Reading (Ω)

Meter Scale
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 b
A
68 C6
C
d
e
69
70
17 33 50 66 S114 S115 48982
a- ECM connector
b- Oil pressure sensor
c- Black/orange
d- Lt blue
e- Purple/yellow
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.
2. Remove the oil pressure sensor from the cylinder block.
a - Engine harness connector

a
48688

Ignition
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 –

Ignition
Notes:

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-5 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


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)

Fusible link 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

60575
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.

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.

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

Copper Battery Cable Wire Gauge Size

Wire Gauge Size Number SAE
OptiMax, Verado,
6–25 hp (2 and
25–115 hp (except 125–250 hp (except 75–115 EFI
Models 4‑Stroke 400 cc
OptiMax) OptiMax) FourStroke (2006
[24.4 in³] or less)
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
7.3 m (24 ft) 2 1 2 1
Length
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
Replacement Parts
! WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with
federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system
components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and
tighten all components.
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.
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.
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
48080


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.
NOTE: For signs of alternator belt failure refer to Section 1B ‑ Alternator 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.
NOTE: The battery must be fully charged prior to beginning these tests.
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.
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.
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.
a - Insulator boot (fusible link)

b
48080
5. Loosen the front alternator screw.

6. Remove the rear alternator screw.

48081
7. Push the alternator toward the front of the engine.
48137
8. Remove the alternator belt.
48138

9. Remove the front screw and the alternator.
48140
Alternator Installation
torque.
48140

48141

48143

71399



b
48080


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

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.

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.

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

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 less
Measure the voltage between the starting than 12.6 volts: check the condition of the battery and load test the
battery terminals. 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 ground). • Ensure the battery cable connections are tight on the battery
and on the powerhead.
Test 1 • Ensure the battery cables are 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 3 (power stud) and test point 2 (common • Ensure the nuts are torqued to specifications at test points 1
powerhead ground). and 3.
• Ensure the cable connection is not corroded.
Measure the battery voltage between test Voltage reading should be the same as test point 1. Voltage
point 8 (ECM and engine sensor ground) and reading less than test point 1:
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
Check for battery voltage at test point 4 defective.
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 powerhead defective.
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.
Connect the meter at test point 2, between the • Check for a loose or corroded battery negative cable
Test 3 connection at the powerhead and the battery.
common powerhead ground and the battery
negative post. • Check for an open battery negative cable.
Continuity indicated ‑ proceed to Test 4.

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 solenoid • Starter solenoid pull‑in coil is good.
at test point 7. Measure the resistance between the exciter
Test 2 • Ensure battery is fully charged.
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

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

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)

b - M10 x 45 flange head screw
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.

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

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

Notes:

Accessory Wire Diagrams
Electrical
Section 2C - Accessory Wire Diagrams
Table of Contents 2
C
Wire Color Code Abbreviations......................................... 2C-2 Battery Isolator Wiring Diagram ‑ 150 FourStroke
Boat Sensor....................................................................... 2C-2 Models.................................................................. 2C-10
Boat Sensor Harness Test......................................... 2C-2 Tilt Limit Module...............................................................2C-10
Digital Speedometer (Optional Sensor) ............................ 2C-3 Tilt Limit Module Installation..................................... 2C-10
SmartCraft Speedometer Sensor Installation............. 2C-4 Calibration Instructions for the Tilt Limit Module 150
Digital Speedometer Harness Test.............................2C-5 EFI FourStroke......................................................2C-11
Digital Block Water Pressure (Optional Sensor)................2C-6 Digital to Analog Conversion........................................... 2C-12
Digital Block Water Pressure Sensor Installation....... 2C-6 Options..................................................................... 2C-12
Digital Block Water Pressure Harness Test............... 2C-7 Digital Trim Sender Converter Kit Installation...........2C-13
Battery Isolator Installation and Wiring Diagram................2C-8 Analog Gauge Interface Installation......................... 2C-14
Installation Instructions (150 Models)......................... 2C-8


Terminal connections
25 Liquid Neoprene 92- 25711 3
Ground screw
66 Loctite 242 Threadlocker Ground screw threads 92-809821
Special Tools

V Hz
H z TEMP
mA
A
mV IG
OFF IP
TEMP
A mA COM V Hz
4516

BLK Black BLU Blue
BRN Brown GRA Gray
PNK Pink PPL Purple
RED Red TAN Tan
LT Light DK Dark
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
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 chartplotter technologies.
a - Speedometer hose
b
b - Electrical cover
c - Digital speedometer
a sensor
d - Engine harness
connector
c d
49492

SmartCraft Speedometer Sensor Installation

1. Push the adapter fitting into the Legris straight fitting. Ensure that the conduit clip is secured around the pressure sensor.
c a- Adapter fitting
a d b- Legris straight fitting
b c- Conduit clip
d- Pressure sensor
48523
2. Locate the engine harness connector for the SmartCraft speedometer sensor and remove the cap.
48524
3. Connect the engine harness connector to the SmartCraft speedometer sensor.

4. Route the speedometer hose toward the adapter fitting and cut the hose to an appropriate length.
5. Push the speedometer hose onto the fitting.

6. Insert the conduit clip into the hole located on the bottom of the electrical cover.
a - Speedometer hose
b
b - Electrical cover
c - Engine harness
a connector
c
48525
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.
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
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
Digital Block Water Pressure Sensor Installation

1. Locate the engine harness connector for the block water pressure sensor and remove the cap.
2. Locate the plug on the exhaust manifold and remove the plug.

a b - Plug
48521
3. Thread the pressure sensor into the exhaust manifold. Tighten the pressure sensor securely. Ensure the lock release is
accessible.

4. Connect the engine harness connector to the block water pressure sensor.
48522
Digital Block Water Pressure Harness Test

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
56203

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
Battery Isolator Installation and Wiring Diagram

Installation Instructions (150 Models)
1. Remove the outboard battery cables from the battery.
2. Install the battery isolator following the manufacturer's instructions.
4. Remove the three screws that secure the electrical plate to the engine, and pull the electrical plate away from the engine
block.
5. Locate the power stud on the electrical plate. Remove the fused alternator cable from the power stud.
a- Power stud
b- M8 x 10 screw
c- Fused alternator cable
d- Electrical plate
d
c
b
a
57347
6. Locate the M8 x 10 screw immediately above the power stud. Remove it from the electrical plate.
7. Slide the ring terminals on the ends of the fused alternator cable and the supplied red cable with black sleeve onto the M8
x 10 screw, and insert the screw back into the threaded hole in the electrical plate.
AWG Cable Requirements

Alternator Output 51‑75A
Total Length Cable Size
3.0 m (10 ft) 6 AWG
4.6 m (15 ft) 4 AWG
6.1 m (20 ft) 3 AWG
7.6 m (25 ft) 2 AWG
9.1 m (30 ft) 2 AWG
12.2 m (40 ft) 0 AWG
15.2 m (50 ft) 2/0 AWG
18.3 m (60 ft) 2/0 AWG
21.3 m (70 ft) 3/0 AWG
24.4 m (80 ft) 4/0 AWG

8. Tighten the M8 x 10 screw to the specified torque.
a - Fused alternator cable

b - M8 x 10 screw
c - Red cable with black sleeve
57348

M8 x 10 screw 24 – 17.7
9. Route the red cable with black sleeve out through the grommet and connect it to the battery isolator per the battery isolator
manufacturer's instructions.
IMPORTANT: For battery isolators, be certain to:

• Observe the proper stacking order: jam nut on the bottom, then the ring terminal, then the lockwasher, and then
the hex nut.
• Hand‑tighten the jam nut. Hold the jam nut with a wrench to prevent it from overtightening, while tightening the hex
nut.
10. Secure the red cable to the engine harness using cable ties.
a - Red cable with black sleeve

b - Cable tie
b
57349
11. Coat all terminal connections with Liquid Neoprene.

25 Liquid Neoprene Terminal connections 92- 25711 3
12. Install the electrical plate.
14. Connect the outboard battery cables to the battery.
15. Connect the isolator output terminals to the batteries. Use a minimum length rated cable, following the isolator
manufacturer’s instructions.

Battery Isolator Wiring Diagram ‑ 150 FourStroke Models
a
j
b
c h l
g
d
f
h
e
i
57301
a- Fused alternator cable

b- M8 x 10 screw in electrical panel
c- Power stud in electrical panel
d- Starter cable
e- Battery positive (+) cable
f- Red cable with black sleeve ‑ route to power stud
g- Battery isolator
h- Fused battery isolator cables ‑ obtain locally
i- Battery ground (–) cable
j- Auxiliary battery
k- Start battery
l- Black cable
Tilt Limit Module

Tilt Limit Module Installation
1. Remove the battery cables from the battery.
2. Disconnect the 3‑pin trim position sensor connectors.
3. Disconnect the cowl‑mounted trim switch connectors.

4. Disconnect the blue/white wire bullet connectors.
a - 3‑pin trim position sensor

connectors
b - Blue/white wire bullet
connectors
c - Cowl‑mounted trim switch
connectors
a b c
48825
5. Connect the tilt limit module 3‑pin connectors in line with the engine harness and the trim position sensor.
6. Connect the tilt limit module blue and blue/white bullet connector in line with the engine harness blue/white bullet
connectors.
7. Connect the tilt limit module trim switch connectors in line with the cowl‑mounted trim switch connectors.
8. Route the tilt limit module harness underneath the flush hose as shown.
9. Bundle the trim position sensor wires, trim switch wires, and the blue and blue/white wires with a cable tie.
10. Bundle the tilt limit module harness and trim position sensor harness with a cable tie.
11. Secure the tilt limit module to the engine harness with a cable tie.
e
a c d
g
b b f
48832
a- Engine harness
b- Cable tie (3)
c- Tilt limit module harness
d- Tilt limit module trim switch harness
e- Flush hose
f- Cowl‑mounted trim switch connectors
g- Orange calibration bullet connector
Calibration Instructions for the Tilt Limit Module 150 EFI FourStroke
NOTE: The minimum tilt limit is approximately 25° up from the engine vertical position.
IMPORTANT: The calibration instructions must be followed exactly for the tilt limit module interface to function correctly and
accurately.
IMPORTANT: There should be several inches between the engine cowl and the motor well in the full tilt position. The tilt limit
module tolerance is ± 5° from the calibrated set point.
1. Tilt the engine to the full down position.

2. Turn the ignition key switch to the OFF position.
3. Install the orange calibration wire into the tilt limit module orange calibration wire.
4. Ground the orange calibration wire onto a clean engine ground location.
a - Tilt limit module orange

calibration wire
b - Orange calibration wire
d
c - Clean engine ground
b location
d - Orange calibration wire
c ring terminal
48833
5. Tilt the engine up to the desired location.

NOTE: If the engine position is above the desired location, tilt the engine below the desired location and then tilt the engine
up. The tilt limit can only be set while the engine is being tilted up for more than a ½ second.
6. Remove the orange calibration wire from the ground location.
7. The tilt limit is now a memorized set point.
8. Trim the engine below the memorized set point.
9. Trim the engine up to confirm the trim limit set point is memorized.
10. Install the male plug into the tilt limit module orange calibration wire bullet connector.
NOTE: After calibrating the tilt limit module, SmartCraft gauges displaying trim position must be recalibrated because of the
increased resistance in the circuit.
Digital to Analog Conversion

Options
This 150 FourStroke outboard is equipped for digital accessories and gauges and requires some conversion when using analog
gauges. There are two options when converting to analog.
Option 1: Digital trim sender converter kit
Option 2: Analog gauge interface (AGI) kit

Digital Trim Sender Converter Kit Installation

! 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.
48635
Trim position adapter harness
1. Remove the battery cables from the battery.

3. Disconnect the trim position sensor harness connector.
4. Remove the cap from the brown/white wire bullet connector.
a a - Trim position sensor harness connector

b - Brown/white wire bullet connector
b
48761
5. Connect the trim position adapter harness in line with the engine harness.
6. Connect the trim position adapter harness brown/white bullet connector to the brown/white wire engine harness connector.
7. Route the black/white trim position adapter harness wire behind the electrical cover as shown.
8. Remove the engine ground screw. Clean any neoprene from the underside of the flange head.
9. Apply Loctite 242 Threadlocker to the ground screw threads.
10. Attach the black/white wire ring terminal connector to the engine block. Secure all ground leads with the screw. Tighten the
screw to the specified torque.

Ground screw (M6 x 16 flange head) 7 62 –

11. Apply Liquid Neoprene to the ground screw.
a - Trim position adapter harness

connectors
b - Brown/white wire bullet
connectors
c - Black/white trim position adapter
harness wire
d - Ground screw (M6 x 16 flange
head)
c c
d
a 48762

25 Liquid Neoprene Ground screw 92- 25711 3
66 Loctite 242 Threadlocker Ground screw threads 92-809821

13. Connect the battery cables to the battery.
Analog Gauge Interface Installation

NOTE: The analog gauge interface (AGI) module can be used on MerCruiser or Outboard models with the 14‑pin non‑DTS
digital or the 14‑pin Digital Throttle and Shift (DTS) systems. Use the ring terminals on the AGI adapter harness to connect to
analog gauges. Tape back any unused terminals. Tachometers with pulse adjusting capability, must be set to 4P (or 8 Cyl).
WIRE CONNECTIONS
GND - GROUND
IGN - 14 VOLTS D.C./IGNITION
5
CAL.
NOTE:
DO NOT TURN
LT - LAMP
SEND.
4 CYCLE GAS-NEG. SIDE OF COIL
4 6
CALIBRATION O/B W/ALT. -ALTERNATOR
POT PAST IT’S
LIMITS
GND. 5
4 6
3
3
2
2
IGN. SEND.
15231
NOTE: For SmartCraft System Link gauges, use the 3‑pin System Link connection on the AGI adapter harness. The AGI
system can support 10 System Link gauges per helm, 2 helms maximum.
IMPORTANT: Mount the AGI module with potted wires facing down to prevent moisture collecting at base of wires and wicking
into the AGI module. Route and secure all wires and harnesses away from hot or moving parts.
1. Mount the AGI module securely under dash or helm with the wires facing down, in close proximity to gauges.
2. Refer to the following table for the AGI adapter harness wire connections. Tape back any unused terminals. Secure
connections per gauge manufacturer's specifications.

Analog Gauge Type AGI Adapter Harness Wire Color

Tachometer Gray
Oil pressure/oil level Blue
Water temperature Tan
Trim positions Brown/white
Fuel level Pink/black
a b c GRY
PNK/BLK
BRN/WHT
TAN
d
BLU
f e 3688
a- AGI module
b- 14‑pin connection
c- AGI adapter harness
d- Analog gauge terminal connections
e- 3‑pin System Link connection
f- AGI 10‑pin connection
3. Ensure a 12‑volt positive (+) power source from the key switch is connected to the analog gauges.
4. Ensure analog gauges are connected to a common engine ground.
5. Connect any SmartCraft System Link gauges to the 3‑pin System Link connection.
6. Connect the AGI adapter harness to the AGI module.
7. Ensure the command module harness 10‑pin junction box connector is connected to the AGI adaptor harness 10‑pin
connector.
• If VesselView is not used, plug the AGI 10‑pin adapter directly into the command module harness 10‑pin junction box
connector.
• If VesselView is used, a junction box and a harness adapter is required. Plug the command module harness 10‑pin
junction box connector, the VesselView harness 10‑pin junction box connector, and one end of the harness adapter
into the junction box. Plug the AGI 10‑pin harness adapter into the harness adapter. Install weather caps on all
unused junction box ports.

Notes:

Descriptive Fault List
Electrical
Section 2D - Descriptive Fault List
Table of Contents 2
D
Descriptive Fault List......................................................... 2D-2

Special Tools

60575

Refer to the following table for an explanation of faults and possible solutions when using the CDS G3 diagnostic interface tool.
Warning Horn
Fault Name Fault Explanation Possible Root Cause
Type
BaroRange No horn Barometer reading out of specification Bad MAP sensor or sensor circuit
Engine is running below specified Possible thermostat failure from excessive
Cold_Engine No horn
running temperature for 8 minutes debris or corrosion
Critical Fault is calibrated to trigger fault at 15 V Alternator sense lead shorted or bad
DRVPInputHigh
6 second beep or 550 ADC alternator
Critical Bad battery connections, weak battery, too
DRVPInputLow Low battery voltage
6 second beep much electrical load, failed alternator
Noncritical Engine Cooling Temperature circuit has
ECTInputHigh Possible sensor or wire failure
6 beeps failed electrically open
Noncritical ECT circuit has failed electrically
ECTInputLow Possible sensor or wire failure to ground
6 beeps shorted
Critical ECT circuit exceeded maximum Water pump failure, debris in cooling
ECT_Overtemp
6 second beep allowable operating temperature system, or failed thermostat
Noncritical Ignition circuit failed open while the
EST1_OutputFault Ignition coil, wire harness, or ECM failure
6 beeps engine was running
Noncritical Ignition circuit failed open while the
EST2_OutputFault Ignition coil, wire harness, or ECM failure
6 beeps engine was running
ESTOP_Active No horn ESTOP was activated Lanyard is pulled, failed switch, or harness
Failure to the sensor or wire harness. Could
EncoderFaultCrank Critical
Crankshaft position sensor circuit failure also be a poor connection that is creating
CamTrigger 6 second beep
too much resistance/load on the circuit.
Critical Current draw from the fuel pumps is Contamination in the electric fuel pumps or
FuelPumpCurrentHigh
6 second beep over specification failure of the pumps
Critical Current draw from the fuel pumps is Fuel pump circuit has failed open due to a
FuelPumpCurrentLow
6 second beep below specification bad harness or pump
Guardian_Active_Fault No horn Refer to active fault Refer to active fault
Noncritical Oil pressure is below specification for Low on oil, bad oil pump, or pressure relief
Guardian_OilPressure
6 beeps engine's speed valve
Noncritical Engine is running above specified Failed water pump, thermostat, or debris
Guardian_Overheat
6 beeps overheat temperature causing water restrictions
Guardian_Overspeed No horn Maximum RPM exceeded Engine is incorrectly propped
Battery voltage is out of specification.
Critical See DRVPInputHigh or DRVPInputLow fault
Guardian_Voltage This fault should accompany
No horn explanations
DRVPInputHigh or DRVPInputLow.
Noncritical
HORN_OutputFault ECM sensed the horn circuit is open Horn is disconnected or bad wire harness
No horn
Noncritical Intake air temperature circuit is Failed intake air temperature sensor or open
IATInputHigh
6 beeps electrically open in the wire harness

Warning Horn
Type
Noncritical Intake air temperature circuit is Failed intake air temperature sensor or short
IATInputLow
6 beeps electrically shorted in the wire harness
Noncritical
INJ1_OutputFault Shorted injector 1 circuit Failed injector or wire harness
6 beeps
Noncritical
6 beeps
Noncritical
6 beeps
Noncritical
6 beeps
If the crank request signal is 2 V lower than
Noncritical Detects if a key switch has a faulty
KeySw_Dirty the wake input into the PCM the fault will
6 beeps crank terminal
become active
If the key is turned on (not cranking) and the
Detects if there is current leaking from
Noncritical voltage on the crank request line is between
KeySw_Leaky the power terminal of the key switch to
6 beeps 3 V and 9.5 V (crank request threshold) the
the crank terminal
fault will be activated
Noncritical Idle Air Control circuit has experienced IAC has electrically failed, wire harness is
LIAC_OutputFault
6 beeps an open or short electrical failure open or shorted
Manifold Air Pressure circuit is
Noncritical
MAPInputHigh electrically shorting the sense lead to 5 Internally shorted sensor or harness
6 beeps
V power
Noncritical MAP circuit has 0 V present on the MAP sensor is open, engine harness has an
MAPInputLow
6 beeps sense lead open, or 5 V sensor power is 0
Noncritical Fault only occurs at idle. MAP must be
MAPR_TPS1Rationality Failed MAP sensor
6 beeps greater than baro pressure.
Plugged MAP sensor, faulty connection, or
Noncritical MAP pressure reading does not agree sensor. Check that both the MAP,TPS, and
MAP_Rationality
6 beeps with TPS reading Intake Air Temp sensors are reading
properly.
Engine RPM exceeds the neutral Engine running in neutral above 2500 RPM,
Neutral_Overspeed No horn
overspeed setting or bad shift position sensor
Critical Engine running with oil pressure below Bad oil pressure sensor/switch, low engine
OilPress_Low
6 second beep calibration set points oil pressure, failed oil pump, oil dilution
Noncritical
OilPressureInputHigh Oil pressure sense lead has 5 V present Failed sensor or engine harness
6 beeps
Noncritical
OilPressureInputLow Oil pressure sensor has an open circuit Failed oil pressure sensor or engine harness
6 beeps
Boat harness failed open or gauge failure.
Noncritical Troll control cannot detect the
RxDoc2_SOH Also check for proper CAN bus termination
6 beeps controlling gauge or device
resistance.
Faulty engine harness, solenoid, or switch.
Critical A shorted coil detected on the start
STRT_OutputFault Check relay coil and wiring for a short
6 second beep relay
circuit.
Security_Device_ Critical Security Theft Deterrent System error or Theft Deterrent System harness
Missing 6 beeps component missing disconnected, failed open, or module failure
Noncritical The engine has been started without No key fob or the incorrect key fob is
Security_Locked
6 beeps recognizing a key fob installed. Possible open in the harness.
Noncritical Theft Deterrent System installed but not The set up procedure was not correctly
Security_Setup
6 beeps correctly recognized by the system followed
Noncritical Shift position sensor has 5 V present on
ShiftPosInputHigh Shorted sensor, engine harness, or ECM
6 beeps the sense lead
Noncritical Shift position sensor has 0 V present on Failed sensor,
ShiftPosInputLow
6 beeps the sense lead ECM or open in the engine harness

Warning Horn
Type
Faulty shift position sensor or wiring. Check
The shift potentiometer is indicating
Noncritical that the shift potentiometer is reading
Shift_Potentiometer neutral when the engine is running over
6 beeps properly (reads in gear while engine is in
a calibrated speed and load
gear).
The engine did not start in calibrated amount
of time and start sequence was aborted.
Engine has lost crank position during
SmartStartAbort No horn Check for faulty key switch or possible
the smart start operation
hydrolock condition. Low battery may also
contribute to this fault.
Noncritical Throttle Position Sensor has 5 V
TPS1_RangeHigh Shorted TPS or engine harness
6 beeps present on the sense lead
Noncritical Failed TPS, open engine harness, or 0 V on
TPS1_RangeLow TPS has 0 V present on the sense lead
6 beeps sensor power
Noncritical TPS voltage is out of specified range The throttle is moved prior to turning the key
TPS_AdaptMech
6 beeps when the key switch is turned on on, or the TPS has been tampered with
TPS value falls below minimum
Noncritical
TPS_Rationality specification while running at or above Bad TPS or linkage problem
6 beeps
the RPM threshold
Noncritical Trim position has 5 volts on the sense
TrimPosHallInputHigh Shorted engine harness or sensor
6 beeps lead
Noncritical Trim position has 0 volts on the sense
TrimPosHallInputLow Open engine harness or sensor
6 beeps lead
Noncritical Water is present in filter, failed sensor, or
WaterInFuelInputLow Water in fuel has 0 V on the sense lead
6 beeps harness
Critical Sensor power (XDRPa) is above
XDRPaInputHigh Failed ECM
6 second beep specification
Sensor power (XDRPa) is below
Critical Shorted out sensor power due possibly from
XDRPaInputLow specification ‑ this is engine sensor
6 second beep bad 3 wire sensor, harness, or ECM
power
Noncritical Sensor power (XDRPb) is above
XDRPbInputHigh Failed ECM
6 beeps specification ‑ this is boat sensor power
Noncritical Sensor power (XDRPb) is below Shorted out sensor power due possibly from
XDRPbInputLow
6 beeps specification ‑ this is boat sensor power bad 3 wire sensor, harness, or ECM

Mercury Universal Fault Code
Electrical
Section 2E - Mercury Universal Fault Code
Table of Contents 2
E
Mercury Universal Fault Codes..........................................2E-2 Mercury Universal Fault Code Table—150 FourStroke..... 2E-2

Mercury Universal Fault Codes

Mercury universal fault codes help ensure uniformity in fault reporting in control modules. It also ensures that boat operators
receive consistent information and instruction, such as Service Engine Soon, Reduce Engine Speed, and others in response
to specific faults.
For CDS G3 users this means that instead of seeing a fault such as INJ1_OutputFault, the fault will now appear as 201 (Fuel
injector circuit 1), 16 (The ECU has detected a problem when trying to output a signal to this device.).
a b c d
56697
An active fault list example (actual screen appearance may vary)

a - Fault code (the affected component)
b - Fault type code (how it was affected)
c - Code description
d - Fault code type description
In the last line of this example, component 203, Fuel injector circuit 3, had a fault type 16, meaning that the ECM/PCM is
unable to output a signal to the device. This could indicate a faulty fuel injector, or in this case, where the same fault is affecting
multiple injector and other components, likely indicates a more widespread fault, such as an unplugged harness, issues with a
power supply, or some other systemic issue.
Mercury Universal Fault Code Table—150 FourStroke

Refer to the following table for a description of universal faults.
Fault Type
Code Description Type Description Possible Root Cause
Code Code
The ECU has detected a problem
Ignition coil, wire harness, or ECM
101 16 Ignition circuit 1 when trying to output a signal to
failure
this device.
Ignition coil, wire harness, or ECM
102 16 Ignition circuit 2 when trying to output a signal to
failure
this device.
201 16 Fuel injector circuit 1 when trying to output a signal to Failed injector or wire harness
this device.

Fault Type
Code Code
this device.
this device.
this device.
The signal or result is outside the
17 Throttle position sensor A Bad TPS or linkage problem
expected range.
The input circuit for the sensor is
301 24 Throttle position sensor A Shorted TPS or engine harness
above the valid limit.
The input circuit for the sensor is Failed TPS, open engine harness, or
25 Throttle position sensor A
below the valid limit. 0 V on sensor power
Throttle position sensor A The throttle is moved prior to turning
The device, calculation, or process
351 6 on mechanical throttle the key on, or the TPS has been
detected a fault.
adapt tampered with
MAP pressure reading does not agree
Manifold pressure sensor The device, calculation, or process with TPS reading. Check that the
6
using time sampling detected a fault. MAP, TPS, and IAT sensors are
reading properly.
401
Manifold pressure sensor The input circuit for the sensor is
24 Internally shorted sensor or harness
using time sampling above the valid limit.
Manifold pressure sensor The input circuit for the sensor is MAP sensor is open, engine harness
25
using time sampling below the valid limit. has an open, or 5 V sensor power is 0
Manifold pressure sensor
The device, calculation or process
404 6 and throttle position sensor Failed MAP sensor
detected a fault.
A rationality
Manifold pressure sensor The signal or result is outside the
407 17 Bad MAP sensor or sensor circuit
barometer reading expected range.
24 Oil pressure Failed sensor or engine harness
above the valid limit.
The input circuit for the sensor is Failed oil pressure sensor or engine
25 Oil pressure
431 below the valid limit. harness
Bad oil pressure sensor/switch, low
Relative to a specified threshold,
21 Oil pressure engine oil pressure, failed oil pump, oil
the value is too low.
dilution
Intake manifold air The input circuit for the sensor is Failed intake air temperature sensor
24
temperature above the valid limit. or open in the wire harness
511
Intake manifold air The input circuit for the sensor is Failed intake air temperature sensor
25
temperature below the valid limit. or short in the wire harness
Engine coolant The input circuit for the sensor is
24 Possible sensor or wire failure
temperature S1 above the valid limit.
Engine coolant The input circuit for the sensor is Possible sensor or wire failure to
523 25
temperature S1 below the valid limit. ground
Engine coolant A temperature sensor value is Water pump failure, debris in cooling
20
temperature S1 higher than normal. system, or failed thermostat
Engine coolant Relative to a specified threshold, Possible thermostat failure from
524 21
temperature S2 the value is too low. excessive debris or corrosion
The signal received is valid but is
4 Sensor supply voltage A Failed ECM
higher than the expected range.
601 Shorted out sensor power due
5 Sensor supply voltage A possibly from bad 3 wire sensor,
lower than the expected range.
harness, or ECM

Fault Type
Code Code
4 Sensor supply voltage B Failed ECM
higher than the expected range.
602 Shorted out sensor power due
5 Sensor supply voltage B possibly from bad 3 wire sensor,
lower than the expected range.
harness, or ECM
The input circuit for the sensor is Alternator sense lead shorted or bad
24 System voltage
above the valid limit. alternator
621 Bad battery connections, weak
25 System voltage battery, too much electrical load,
below the valid limit.
failed alternator
The trim sensor is either open or
Engine or drive trim The input circuit for the sensor is
24 shorted to ground.
position above the valid limit.
1012 Check trim sensor and wiring.
Engine or drive trim The input circuit for the sensor is The trim sensor is shorted to power.
25
position below the valid limit. Check the trim sensor and wiring.
The shift potentiometer indicates
neutral when the engine is running
The device, calculation, or process over a calibrated speed and load.
6 Shift position potentiometer
detected a fault. Check that the shift potentiometer is
reading properly (reads in gear while
1022 engine is in gear).
The input circuit for the sensor is Shorted sensor, engine harness, or
above the valid limit. ECM
The input circuit for the sensor is Failed sensor,
below the valid limit. ECM or open in the engine harness
Failure to the sensor or wire harness.
Crankshaft or camshaft The device, calculation, or process Could also be a poor connection that
1052 6
trigger detected a fault. is creating too much resistance/load
on the circuit.
If the crank request signal is 2 V lower
The signal following a switch is
7 Key switch than the wake input into the PCM the
below the expected value.
fault will become active
1107 If the key is turned on (not cranking)
and the voltage on the crank request
The signal following a switch is
8 Key switch line is between 3 V and 9.5 V (crank
above the expected value.
request threshold) the fault will be
activated
The input circuit for the sensor is Water is present in filter, failed sensor,
1108 25 Water in fuel
below the valid limit. or harness
A particular state or condition Lanyard is pulled, failed switch, or
1109 23 Emergency stop
exists. harness
A particular state or condition
2011 23 Guardian Refer to active fault
exists.
Guardian due to oil A particular state or condition Low on oil, bad oil pump, or pressure
2051 23
pressure exists. relief valve
A particular state or condition Failed water pump, thermostat, or
2081 23 Guardian due to overheat
exists. debris causing water restrictions
2091 23 Guardian due to overspeed Engine is incorrectly propped
exists.
A particular state or condition Engine running in neutral above 2500
2092 23 Neutral overspeed
exists. RPM, or bad shift position sensor
A particular state or condition Refer to universal fault code 621‑24 or
2111 23 Guardian due to voltage
exists. 621‑25
Relative to a specified threshold,
2152 22 Manifold airflow Throttle restrictor has been removed
the value is too high.

Fault Type
Code Code
The output signal from the ECU to
Fuel pump circuit has failed open due
1 Fuel pump the device is open circuit or has
to a bad harness or pump
too much resistance.
3061
The output signal from the ECU to
Contamination in the electric fuel
2 Fuel pump the device is short circuit or has
pumps or failure of the pumps
too little resistance.
Horn is disconnected or bad wire
3152 16 Warning horn when trying to output a signal to
harness
this device.
IAC has electrically failed, wire
3161 16 Idle air control valve when trying to output a signal to
harness is open or shorted
this device.
The ECU has detected a problem A shorted coil detected on the start
3171 16 Starter when trying to output a signal to relay. Check relay coil and wiring for a
this device. short circuit.
The engine did not start in calibrated
amount of time and start sequence
A particular state or condition was aborted. Check for faulty key
3172 23 Smart Start aborted
exists. switch or possible hydrolock
condition. Low battery may also
contribute to this fault.
Boat harness failed open or gauge
CAN P Doc 02 state of The device, calculation or process
4005 6 failure. Also check for proper CAN bus
health detected a fault.
termination resistance.
Theft Deterrent System harness
4501 23 Security device missing disconnected, failed open, or module
exists.
failure
No key fob or the incorrect key fob is
4502 23 Security locked installed. Possible open in the
exists.
harness.
A particular state or condition The set up procedure was not
4503 23 Security setup
exists. correctly followed

Notes:

Theory of Operation
Fuel System
Section 3A - Theory of Operation
Table of Contents
3
Fuel Supply System Hoses................................................3A-4 Intake Manifold......................................................... 3A-15
Fuel Supply Module (FSM) Components ‑ SN 2B458410 Engine Control Module (ECM)..................................3A-15
and Below ......................................................................3A-6 Throttle Body............................................................ 3A-15
Fuel Supply Module (FSM) Components 2B458411 and
Above............................................................................. 3A-8
Idle Air Control (IAC).................................................3A-16
Fuel Supply Module (FSM)....................................... 3A-16
A
Integrated Air Fuel Module and Fuel Rail Components... 3A-10 Fuel Lift Pump...........................................................3A-17
Integrated Air Fuel Module Components......................... 3A-12 High‑Pressure Fuel Pump........................................ 3A-18
Air Induction System........................................................ 3A-14 Fuel Pressure Regulator...........................................3A-18
Fuel Injection System.......................................................3A-14 In‑Line Fuel Filter—Design 1.................................... 3A-19
Air Induction and Fuel Injection System...........................3A-14 In‑Line Fuel Filter—Design 2.................................... 3A-19
Fuel System Description...........................................3A-14 Fuel Injector.............................................................. 3A-19
Main Power Relay (MPR)......................................... 3A-15 Guardian Protection System............................................ 3A-19

Theory of Operation
Special Tools

60575

Theory of Operation
Notes:

Theory of Operation
Fuel Supply System Hoses
1 20 6 2
7
3
22 6
8
4
21
22 5
4
3
2
10
11
19
12 18
15
13
14
16
17
61623

Theory of Operation
Fuel Supply System Hoses

Torque
1 1 Manifold reference hose
2 2 Metal clamp (16.2 mm)
3 2 Hose
5 1 Fuel filter
6 2 Cable tie
7 1 Reusable sleeve
8 1 Hose
9 1 Fuel filter retainer
10 1 O‑ring
11 1 Grommet
12 1 Bushing
13 1 Grommet
14 1 Washer
15 1 Screw (M6 x 25) 10 88.5 –
16 1 Hose retainer
17 1 Plastic screw
18 1 Hose
19 1 In‑line fuel filter
20 1 Filter
21 1 Hose
22 2 Clamp

Theory of Operation
Fuel Supply Module (FSM) Components ‑ SN 2B458410 and Below

1
2
20
22
21
13
3
23 14
15
4
7 5
13
6 8 16
9
17
10
7 16
12
18
11
7
10 19
48372

Theory of Operation
Fuel Supply Module (FSM) Components - SN 2B458410 and Below

Torque
1 4 Screw 10 88.5 –
2 1 FSM top housing
3 1 O‑ring
4 1 Regulator assembly
5 1 O‑ring
6 1 O‑ring
7 3 Seal
8 2 O‑ring
9 1 FSM cap
10 2 Seal
11 1 Low‑pressure pump assembly
12 1 High‑pressure pump assembly
13 4 O‑ring
14 2 Fuel tube
15 1 Suction tube
16 4 O‑ring
17 2 Water tube
18 1 Seal
19 1 FSM bottom housing
20 1 Electrical harness assembly
21 1 O‑ring
22 1 O‑ring
23 1 Spacer

Theory of Operation
Fuel Supply Module (FSM) Components 2B458411 and Above
14
14 15
23 1
15
16 16
22
24 3
25
4
3 17 17
7 6
10
9
15
8 15
14
14
11 18
12
19
13
21
7
11 20
67026

Theory of Operation
Fuel Supply Module (FSM) Components 2B458411 and Above

Torque
1 1 FSM top housing 10 88.5 –
2 4 Screw
3 2 O‑ring
4 1 Spacer
5 1 Regulator assembly
6 1 O‑ring
7 3 Seal
8 1 FSM cap
9 2 O‑ring
10 1 Suction tube
11 2 Seal
12 1 High‑pressure pump assembly
13 1 Low‑pressure pump assembly
14 4 Seal
15 4 O‑ring
16 2 Water tube
17 2 Fuel tube
18 1 Seal
19 1 FSM bottom housing
20 1 Grommet
21 1 Bushing
22 1 FSM harness grommet
23 1 Harness assembly
24 1 O‑ring
25 1 O‑ring

Theory of Operation
Integrated Air Fuel Module and Fuel Rail Components

1
10
2
4 5
8
6
48369

Theory of Operation
Integrated Air Fuel Module and Fuel Rail Components

Torque
1 1 Vent hose assembly
2 4 Fuel injector
3 1 Seal kit
4 4 Fuel injector retainer
5 1 Fuel rail
6 4 Screw (M6 x 20) 8 70.8 –
7 2 Screw (M4 x 16) 1.7 15 –
9 1 Temperature sensor assembly
10 1 Restrictor

Theory of Operation
Integrated Air Fuel Module Components

1
3
4
8
6
7
10
11
25
24 1
14
13
18 22
19
12 17 5
20 23
15 16
22
18 21
19
17
48370

Theory of Operation

Torque
1 6 Screw (M6 x 20) 8 70.8 –
2 1 Throttle body assembly
3 1 Sensor
4 2 Screw (M4 x 16) 2.3 20.3 –
5 1 Intake manifold
6 4 Seal
7 1 Seal
8 1 Link rod
9 1 Socket
10 4 Retainer
11 11 Screw (M6 x 40) 10 88.5 –
12 1 Screw (M4 x 16) 6 53.1 –
13 1 Bracket
14 1 Manifold absolute pressure sensor
15 1 Plastic screw
16 1 Clip
17 2 Shoulder screw 10 88.5 –
18 2 Washer
19 2 Wave washer
20 1 Throttle lever
21 1 Return spring
22 2 Washer
23 1 Throttle link actuator
24 1 Link rod retainer
25 1 Idle air control

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 split sequential multiport injection system. The fuel delivery system, in conjunction with the
ignition system, is controlled by the engine control module (ECM). The ECM requires input data 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) valve 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 by completing the ground circuit through the ECM.
Fuel pressure changes under different operating conditions. When the engine is under low or high demands, the manifold
absolute pressure changes. The demands of the engine are communicated to the ECM through the manifold absolute pressure
(MAP) sensor value and the throttle position sensor value. 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 absolute pressure changes will push or pull the fuel pressure regulator diaphragm, changing the amount
of fuel pressure in the fuel rail. Any excess fuel is recirculated inside the FSM in order to regulate pressure.
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 values are the base for all fueling strategies at start‑up. Fuel strategy changes constantly
during engine operation.
The fuel is water‑cooled inside the FSM. 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 of 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.

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.
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 disengages 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.

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.

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 cooler water out port
c
e- Fuel lift pump (from vessel)
f- Fuel cooler fuel tube
e
d
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

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 that 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

Theory of Operation
In‑Line Fuel Filter—Design 1

The in‑line fuel filter is located in the high‑pressure fuel line feeding the fuel rail. This filter is replaceable and utilizes a reusable
sleeve to protect the filter from static discharge.
a
a - Reusable sleeve
b - In‑line fuel filter
b
61597
In‑Line Fuel Filter—Design 2

The in‑line fuel filter is located on the starboard side of the powerhead, inside the inlet end of the fuel rail, near the bottom of
the intake manifold. This in‑line fuel filter consists of a one way, reusable filter element. The filter can be removed from the fuel
rail and cleaned as part of normal maintenance, or in the event of fuel contamination. Clean the filter element by backflushing it
with a locally available fuel system cleaner. Replacement is not required unless the in‑line fuel filter is damaged, punctured, or
otherwise unsuitable for use.
55858
In-line fuel filter
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.

Theory of Operation
Notes:

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-2 Fuel Pumps........................................................................3B-6
Fuel Supply Module Priming Procedure............................ 3B-3 Fuel Supply Module Fuel Pumps................................3B-6
Priming the FSM with a Fuel Pressure Gauge........... 3B-3
Priming the FSM (Ran out of Fuel Condition) ............3B-4
Fuel Lift Pump ............................................................3B-7
High‑Pressure Fuel Pump.......................................... 3B-8
B
Antisiphon 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-5 Fuel Injector and Harness Voltage Test..................... 3B-9
Idle Air Control (IAC)..........................................................3B-5


25 Liquid Neoprene Grounds and ring terminals 92- 25711 3
Special Tools
Tests the fuel pump pressure; can be used to relieve fuel pressure.
2807

60575

V Hz
H z TEMP
mA
A
mV IG
OFF IP
TEMP
A mA COM V Hz
4516
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
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 Fuel Pressure Gauge

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; contains an antisiphon 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.
a a - Fuel pressure gauge purge valve

b - Schrader valve
c - Purge hose to appropriate container
58370
5. Open the fuel pressure gauge purge valve and turn the ignition key on. The fuel pumps will run for approximately three to
five seconds.
6. Turn the ignition key off and then on. The fuel pumps will run for approximately three to 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.
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 a 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 three to 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. After 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 Fuel Pressure Gauge to prime the fuel system.
Antisiphon Valves
While antisiphon 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 antisiphon 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 antisiphon 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 antisiphon valve is the cause of the problem, there are two solutions to
the problem; either 1) replace the antisiphon 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. The fuel pressure is
factory‑adjusted to a predefined set point. While the regulator is designed to maintain fuel pressure at this set point, some
normal variation occurs with changes in the engine's fuel consumption. With an increase in consumption, less fuel is bypassed
through the regulator, causing a decrease in the set point.

A reference hose is connected between the intake manifold and the pressure regulator. The intake manifold pressure acts on
the regulator diaphragm to adjust the regulated fuel pressure in response to pressure changes in the intake manifold. Intake
manifold vacuum pulls on the fuel pressure regulator diaphragm, resulting in a regulated fuel pressure lower than the factory
set point. The level of vacuum in the intake manifold is directly related to engine speed and throttle position.
Fuel Pressure Calculations, Engine Running

A simple formula can be used to determine what the approximate fuel pressure should be at different points in the engine RPM
range: (MAP – Baro) + regulator set point.
IMPORTANT: The actual regulator set point will vary according to engine fuel consumption, as described preceding. The actual
fuel pressure may therefore fall anywhere within a 60 kPa (8.7 psi) range. In other words, fuel pressures calculated with this
formula have a tolerance of ± 30 kPa (± 4.35 psi).
The following examples assume an ambient barometric pressure of 101 kPa (14.65 psi) and an average fuel pressure set point
of 357 kPa (51.78 psi).
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), then:
• kPa: (32 – 101) + 357 = 288. The calculated fuel pressure reading is 288 kPa; actual fuel pressure is 288 ± 30 kPa.
• psi: (4.64 – 14.65) + 51.78 = 41.77. The calculated fuel pressure reading is 41.77 psi; actual fuel pressure is 41.77 ± 4.35
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.
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.
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 are 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 it recirculates inside the fuel supply module.

The fuel lift pump and high‑pressure pump are on a parallel electrical 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 three seconds when the 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.
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 it recirculates inside the fuel supply module.
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 System Inlet 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.

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. At maximum fuel flow (wide‑open throttle engine operation) the vacuum gauge reading should not exceed the listed
specification.
a- Engine fuel line

b- Clear fuel line
c- T‑fitting
d- Boat fuel line
a d
b c
4439
Fuel System Inlet Vacuum

Maximum 8.5 kPa (2.5 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.
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.
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.

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

Fuel pressure, engine not running 335–375 kPa (48.6–54.4 psi)
Fuel pressure, engine running at idle 280–320 kPa (40.6–46.4 psi)
Fuel pressure, engine running under load Pressure dependent on manifold vacuum pressure, use calculation.
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.

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.

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.

Service Procedures
Fuel System
Section 3C - Service Procedures
Table of Contents
3
Fuel System Specifications................................................3C-2 FSM Disassembly.....................................................3C-10
Throttle Body..................................................................... 3C-2 FSM Assembly......................................................... 3C-13
Throttle Body Removal............................................... 3C-2 FSM Installation........................................................3C-19
Throttle Body Installation............................................ 3C-3
Fuel Rail.............................................................................3C-5
Fuel Supply Module (FSM) 2B458411 and Above.......... 3C-21
FSM Removal...........................................................3C-21
C
Fuel Rail Removal and Disassembly..........................3C-5 FSM Disassembly.....................................................3C-22
Fuel Rail Assembly and Installation............................3C-6 FSM Assembly......................................................... 3C-27
Fuel Supply Module (FSM) 2B458410 and Below.............3C-8 FSM Installation........................................................3C-35
FSM Removal.............................................................3C-8

Service Procedures

Automotive unleaded with a minimum pump posted octane rating
Type of fuel
of 87 (90 RON)
Approximate fuel pressure at idle 280–320 kPa (40.6–46.4 psi)
Approximate fuel pressure engine not running 335–375 kPa (48.6–54.4 psi)
Fuel filtration
Fuel inlet 20 microns
High‑pressure Design 1—20 microns, Design 2—46 microns
Amperage draw* 10 A ± 3 A
*Measurement performed at engine idle, fully primed fuel system (no air entrained) and fully charged battery (normal system
voltage).

O-rings
Seal grommet
95 2-4-C with PTFE Fuel pressure regulator O-rings 92-802859A 1
O-rings and seal grommets
Both 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.
3. Disconnect the throttle link from the throttle body lever.
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

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

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.

7. Connect the throttle link to the throttle body lever.

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.

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.

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.

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 16.2 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) 2B458410 and Below

FSM Removal
1. Release the fuel pressure on the fuel rail. Refer to Fuel Rail Removal.
! CAUTION

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 5A ‑ 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 16.2 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.

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 four screws securing the upper housing to the lower housing.
a - Screw (4)
58113
3. Grasp the lower housing and the upper housing and push the upper housing slightly to partially separate the upper housing
from the lower housing.
4. 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

Service Procedures
5. Carefully lift the upper housing to access the power wire connections.
6. 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
7. Remove the manifold from the tubes and fuel pumps.
a- Manifold
b- Lift fuel pump
c- Tube (4)
a d- High‑pressure fuel pump
b
d
c 49147
8. Remove the tubes and fuel pumps from the lower housing.

Service Procedures
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
9. Remove the seal grommets from the manifold.
a - High‑pressure fuel pump seal grommet

b - Fuel lift pump seal grommet
a
b
49155
10. Remove three O‑rings and a spacer from the manifold.
a - O‑rings
b b - Spacer on fuel pressure regulator
a
49156
11. 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.

Service Procedures
12. Remove the O‑ring and spacer from the fuel pressure regulator.
a - O‑ring
b - Spacer
a
b
49158
13. Inspect the inside of the upper and lower housings for seal grommets and remove them.
49162
14. 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.
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

Service Procedures
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
5. Install the seal grommet halfway onto the high‑pressure fuel pump outlet.
49206

Service Procedures
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 toward 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.

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.

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

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.

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

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

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 –
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.

Screw (M6 x 25) 8 70.8 –
3. Push the fuel hose onto the FSM far enough to lock it in place.

Service Procedures
4. Install the exhaust cooling hose to the fitting and secure with a cable tie.
a- Grommet
c- Cable tie
d- Fuel hose
c 49248
5. Install the FSM cooling water supply hose onto the FSM and secure with a cable tie.
6. Install a 16.2 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
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.

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 5A ‑ Lower Cowl.
13. Purge the fuel supply module. Refer to Section 3B ‑ Fuel Supply Module Priming Procedure.
Fuel Supply Module (FSM) 2B458411 and Above

FSM Removal
1. Release the fuel pressure on the fuel rail. Refer to Fuel Rail Removal.
! CAUTION
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.
3. Remove the remote control harness, fuel line, throttle, and shift cables.
4. Remove the lower cowls. Refer to Section 5A ‑ Lower Cowl.
b a - Screw
b - Cable tie
a
48054

Service Procedures
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.
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 b line
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.
15. Pull the FSM out of the grommet to remove.
a- Grommet
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.

Service Procedures
2. Remove the metal hose clamp securing the high‑pressure hose to the FSM upper housing and remove the hose.
56209
3. Remove the four 1/4 in. hex head screws securing the upper housing to the lower housing.
a - Screws (4) 1/4 in. hex head
49136
NOTE: Use caution when separating the housing. The lower housing may be completely filled with fuel.
4. Grasp the lower housing and the upper housing and pull the upper housing slightly to partially separate the upper housing
from the lower housing. The O‑ring seal is extremely tight, a putty knife or similar tool may be needed to start the
separation process.
5. When a gap between the upper and lower housing is achieved insert two pry tools on opposite sides of the unit, between
the upper and lower housing, and carefully separate the housing.
49141
6. Carefully lift the upper housing to access the power wire connections.

Service Procedures
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
8. Remove the manifold from the tubes and fuel pumps.
a- Manifold
b- Fuel lift 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.

Service Procedures
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 lift pump

b- Fuel tubes
c- High‑pressure fuel pump
b d- Water tubes
63405
10. Remove the seal grommets from the manifold.
a - High‑pressure fuel pump seal grommet

b - Fuel lift pump seal grommet
a
b
49155
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.

Service Procedures
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, O‑rings, or seals 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.
16. Guide the wiring through the housing.
63715
17. Remove any grommets or wire retainers from the harness.
63717

Service Procedures
18. Remove the wire retainer from the rear of the connector.
63718
19. Using a micro screwdriver or similar tool, pry the wire pin off of the holding tab of the connector and push the wire pin free
of the holding tab. Repeat for the second wire.
63719
20. Carefully remove the wires from the connector and remove the harness from the fuel module housing. Make a note as to
the proper position of the wire colors in respect to the connector.
63720
FSM Assembly
1. Install the O‑rings and seals onto the water tubes and fuel tubes.

Service Procedures
2. Lubricate the O‑rings and seals on the tubes with 2‑4‑C with PTFE.
a a
a- O‑rings
c b- Seals
c- Water tube
d- Fuel tube
b d b
a c a
b d b
63404
3. Install the fuel tubes into the lower housing.
63410

4. Install the water tubes.
b a - Water tubes
b - Fuel tubes
63411

Service Procedures
5. Install the seal grommet halfway onto the high‑pressure fuel pump outlet. Install the bottom seal grommet on the
high‑pressure fuel pump.
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 fuel pump and the housing.
63822
63823

Service Procedures

7. Install the bottom seal grommet and the outlet seal grommet halfway onto the fuel lift pump and lubricate with 2‑4‑C with
PTFE.
63826

8. Install the fuel lift pump into the lower housing so the outlet port of the pump faces toward the center of the FSM.
b a- Fuel lift pump

b- Fuel tubes
c c- High‑pressure pump
d- Water tubes
63775
9. Lubricate both seal grommets with 2‑4‑C with PTFE.

95 2-4-C with PTFE Both seal grommets 92-802859A 1
10. Install two O‑rings onto the manifold.
11. Verify that the hole in the manifold is open and that no debris partially blocks the hole.

Service Procedures
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
12. Carefully install the manifold while aligning the fuel pumps and tubes. Verify that the manifold is seated on the fuel pumps.
Ensure that 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
13. Verify that the spacer is installed onto the fuel pressure regulator.
14. Verify that 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.
15. 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

16. Install the fuel pressure regulator onto the manifold.

Service Procedures
17. Install the spacer and O‑ring onto the fuel pressure regulator.
a a - O‑ring
b b - Spacer
49225
18. Install the seal grommet halfway onto the manifold.

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

21. Install new O‑rings onto the fuel pump wire harness seal grommet. Verify that the blue O‑ring is installed on the upper
groove of the seal grommet. Lubricate the O‑rings with 2‑4‑C with PTFE.
22. 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


Service Procedures
23. Align the wire pins with the mounting tabs in the connector and insert the wire pins into the connector. Snap the wire
retainer onto the end of the connector.
63722
24. Connect the red wire from the upper housing to the positive terminal on the fuel lift pump.
25. Connect the black wire from the upper housing to the negative terminal on the fuel lift pump.
26. Connect the high‑pressure fuel pump black wire to the terminal on the fuel lift pump.
27. 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

Service Procedures
28. Verify that the wires will not become pinched and install the upper housing.
49237
29. Carefully push the upper housing into the lower housing until there is no gap between the upper and lower housing. A soft
jawed bench vice and a channel lock pliers may be needed to completely squeeze the unit together.
IMPORTANT: Do not use the screws to close the unit. This can result in stripping of the plastic bosses and cause the unit
to separate.
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.
30. Install the screws and tighten the screws to the specified torque.
a - No gap
b - Screw (4)
a
49240

Screw 10 88.5 –

Service Procedures
31. Install a 16.2 mm (0.75 in.) 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.
56209
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.

Screw (M6 x 25) 8 70.8 –
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
c- Cable tie
d- Fuel hose
c 49248
5. Install the FSM cooling water supply hose onto the FSM and secure with a cable tie.
6. Install a 16.2 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.

Service Procedures
8. Connect the manifold pressure reference line to the FSM.

a b line
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.
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 –
12. Install the lower cowls. Refer to Section 5A ‑ Lower Cowl.
13. Purge the fuel supply module. Refer to Section 3B ‑ Fuel Supply Module Priming Procedure.

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

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.

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.

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:
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 manufacture
kw CO FEL: g/kWh
i
f- US EPA engine family name
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.

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.

Emissions
Notes:

Cylinder Block/Crankcase
Powerhead
Section 4A - Cylinder Block/Crankcase
Table of Contents
Cylinder Block/Crankcase Specifications...........................4A-2 Oil Pump .................................................................. 4A-37
Cylinder Block Components...............................................4A-4 Balance Shaft...................................................................4A-38
Crankshaft, Connecting Rod, Piston, Timing Chain Balance Shaft System Disassembly......................... 4A-38
Components................................................................... 4A-6 Balance Shaft System Assembly..............................4A-40
Flywheel and Cover Components......................................4A-8 Powerhead Assembly...................................................... 4A-42
Exhaust Manifold............................................................. 4A-10
Cylinder Head.................................................................. 4A-12
Cylinder Block Galley Plug Installation..................... 4A-42
Crankshaft Installation.............................................. 4A-43 4
Dressed Powerhead Removal ........................................ 4A-14
Removing Powerhead Components................................ 4A-18
Piston/Connecting Rod Assembly............................ 4A-47
Piston Ring Installation............................................. 4A-47 A
Flywheel Removal.................................................... 4A-18 Connecting Rod Bearing Grade Selection................4A-49
Wire Harness Removal.............................................4A-20 Piston Connecting Rod Assembly Installation.......... 4A-50
Component Removal................................................ 4A-23 Balance Shaft Assembly Installation.........................4A-53
Powerhead Diasssembly ................................................ 4A-27 Bedplate Cover Installation.......................................4A-57
Cylinder Head Removal............................................4A-27 Cylinder Head Installation.........................................4A-58
Cylinder Block Disassembly and Crankshaft Removal Crankshaft Seal Installation...................................... 4A-64
.............................................................................. 4A-29 Oil Pump Installation.................................................4A-66
Cleaning, Inspection, and Repair.....................................4A-32 Installing Powerhead Components.................................. 4A-67
Powerhead Preassembly Cleaning Component Installation............................................. 4A-67
Recommendations................................................ 4A-32 Alternator Installation................................................ 4A-71
Measuring Cylinder Bore.......................................... 4A-32 Wire Harness Installation..........................................4A-73
Measuring Piston...................................................... 4A-33 Powerhead Installation onto the Midsection.................... 4A-77
Measuring Connecting Rod ..................................... 4A-35 Engine Break‑in Procedure..............................................4A-84
Measuring Crankshaft...............................................4A-36


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 0.65–0.80 mm (0.0256–0.0315 in.)
Third (lower ring only) 0.25–0.76 mm (0.0098–0.0299 in.)

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
Fusible link wire connection
25 Liquid Neoprene Ground on cylinder block, fusible link connection on alternator 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 8M0071842
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 and 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 92-8M0078629
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
Piston Ring Compressor Obtain Locally
Compresses piston ring into ring grooves during installation of piston into
cylinder bore.
101.6 mm (4.000 in.)
60579

Used to clamp high pressure (Oetiker ®) hose clamps. Part of Clamp Tool Kit
39648 (91‑803146A4).

Cylinder Block Components

16
14
15
9
17 18
4 13
2 5
3 6
24 1
11
12
7 3
19
10 3
20 22 9
23
21
48376

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 additional 60°
5 1 Dipstick
6 2 O‑ring
7 1 Plug (18 mm) 22 – 16.2
8 1 O‑ring
9 1 Plug (30 mm) 55 – 40.5
10 1 O‑ring
11 1 Plug (24 mm) 55 – 40.5
12 1 O‑ring
13 12 Screw (M6 x 25) 10 88.5 –
14 1 Crankcase cover
15 1 Crankcase cover seal
16 1 Oil fill cap
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
24 2 Thrust washer

Crankshaft, Connecting Rod, Piston, Timing Chain Components
2
4
5
23
24
9 22
21
8
10
18 20
3 11
1
4 19
17
6 16
12 15
7
13
14
48377

Crankshaft, Connecting Rod, Piston, Timing Chain Components

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

Flywheel and Cover Components

1
2
48364

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

Exhaust Manifold
1
2
6
3
4
8
4
3
48381

Exhaust Manifold
Torque
1 1 Gasket
2 1 Manifold
3 2 Plug (18 mm)
4 1 O‑ring
5 1 Fitting
First 15 132.7 –
6 9 Screw (M8 x 60)
Final 28 – 20.6
7 1 Cover
8 4 Plastic screws

Cylinder Head
6
49000

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

Dressed Powerhead Removal

! WARNING

2. Remove the upper and lower cowls. Refer to Section 5A ‑ Lower Cowl Removal.
3. Remove the throttle and shift cables, fuel line, and remote control harness.
4. Drain the oil from the engine. Refer to Section 1B ‑ Changing Engine Oil.
b a - Screw
b - Cable tie
a
48054
7. Cut the cable tie securing the fuel pump connector to the manifold air temperature (MAT) sensor harness.
8. Disconnect the fuel pump connector from the engine harness.
9. Release the fuel pressure on the fuel rail. Refer to Section 3C ‑ Fuel Rail Removal and Disassembly.
! CAUTION
11. Remove the manifold pressure reference line from the fuel supply module (FSM).
12. 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

13. Remove the water dump hose fitting from the adapter plate. Pull the hose out to access the three powerhead mounting
screws.
IMPORTANT: After removing the water dump hose fitting from the adapter plate, cover the opening with a piece of tape.
48531
14. Remove the powerhead mounting screws.
48057
15. 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

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

a b - Shift link
48059
17. Cut the cable tie securing the hose to the water pump indicator fitting.
18. Disconnect the fuel supply hose at the fuel filter outlet port. Remove the filter and attachment from the adapter plate.
19. 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
20. Cut the cable ties securing the hoses to the strainer. Remove the hoses.
21. 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

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

Screws 27 – 20
25. 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.

26. 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
4. Push the alternator toward the front of the engine.
48146

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


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.

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.

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

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

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

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.)
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
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.)

Connecting Rod
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
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
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 8M0071842
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 92-8M0078629
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.
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
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
Balance 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 and screw threads Obtain Locally
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.

IMPORTANT: Make sure the bearings are centered during assembly. A noncentered bearing will cause a powerhead
failure.
a a
61624
a - Center each bearing on the line bore
7. Lubricate the balance shafts bearing contact area, the thrust face area, and the gear teeth with engine assembly lubricant.
47796
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

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.
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
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.

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.
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.
IMPORTANT: The opening of the piston pin retaining clip should face toward 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 toward the flywheel.

139 Piston ring grooves 92-8M0078629
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.
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.)
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
Piston Connecting Rod Assembly Installation

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

139 Piston and rings 92-8M0078629
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
Piston Ring Compressor Obtain Locally
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 92-8M0078629
Outboard Oil 25W-40
6. Install the piston into the cylinder bore with the piston demarcation toward 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.
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 toward 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 –
Rod cap screws Second 25 – 18.4
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 –
Rod cap screws Second 25 – 18.4
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 as not to interfere with the rotation of the crankshaft.
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 counterrotate 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.
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
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.
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 M6 x 25 screws. Tighten the screws to the specified torque.
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 (M6 x 25) 9 79.7 –
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.
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
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 92-8M0078629
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

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
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 92-8M0078629
Outboard Oil 25W-40
16. Secure the camshaft and tighten the screw in two stages to the specified torque.
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

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.
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 8M0071842
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
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
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 8M0071842
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 –
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 44.3 –
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 –
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.
NOTE: Check for damage, cracks, or cuts in the manifold seals.
48271

11. Install the intake manifold onto the cylinder head and secure with 11 M6 x 40 flange head screws. Tighten the screws to
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.

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.

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
Alternator Installation

torque.
48140

48141
48143


71399


b
48080


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.

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.

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.

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.

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.

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 toward 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

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

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

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 – 44.3
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.

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.

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.

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.

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

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
Intake 0.0762 mm (0.003 in.)
Camshaft to roller clearance (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°
Intake 0.38 ± 0.2 mm (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.)

95 2-4-C with PTFE Installing valve spring retainer locks 92-802859A 1

Cylinder Head

Galley plug threads
Synthetic Blend 4-Stroke Valve guide seal
139 92-8M0078629
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

Cylinder Head
Cylinder Head
6
49000

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

Cylinder Head
Cylinder Head and Valve Train Components

7
14
15 1 8
23
16 2
4 20 21 18
19 34 17 13
22
11
12
23
3
8
7 10
9
6
5
24
27
33
31 32
26 30
28
27 25
29 48375

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 53.1 –
12 10 Screw (M6 x 36)
Final 12 106.2 –
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 –

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 toward
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.

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

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

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.)
Intake valve Valve face angle (c) 45°
Outside diameter (d) 50.8 ± 0.13 mm (2.0 ± 0.005 in.)
Valve margin width (e) 0.38 ± 0.2 mm (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

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.)

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.)

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 12 106.2 –
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.

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.

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 92-8M0078629
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 –

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 92-8M0078629
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

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 92-8M0078629
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

Cylinder Head

139 Rocker arm roller bearing 92-8M0078629
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 toward 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.

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 53.1 –
Camshaft cap screws (M6 x 35)
Final 12 106.2 –
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 –

Cylinder Head
4. Check the clearance after tightening the locknut to the specified torque. Adust the clearance as required.

Cylinder Head
Notes:

Lubrication
Powerhead
Section 4C - Lubrication
Table of Contents
Lubrication System Specifications..................................... 4C-2 Disassembly and Inspection.......................................4C-2
Oil Pump ........................................................................... 4C-2 Assembly.................................................................... 4C-3
4
C

Lubrication

Engine capacity with filter replacement 6 liters (6.3 US qt)
Oil pressure

Grease
139 Oil pump 92-8M0078629
Outboard Oil 25W-40
Oil Pump
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 or erosion.
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.

Lubrication
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 92-8M0078629
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.
7. Secure the oil pump cover with seven screws. Tighten the screws to the specified torque in the sequence shown.
2
3
7
4
5
6 62046

Oil pump cover screws (7) 4 35.4 –

Lubrication
Notes:

Cooling
Powerhead
Section 4D - Cooling
Table of Contents
Cooling Specifications....................................................... 4D-2 Thermostat Removal.................................................. 4D-6
Cooling Components......................................................... 4D-4 Thermostat Installation............................................... 4D-6
Thermostat.........................................................................4D-6
4
D

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

60575

Cooling
Notes:

Cooling
Cooling Components
29
30 2 3 4
18
1
5
7 6
24
31
28
23 22
25 8 6
26
13 29
27
14 12
A
15
10
9
16
11
19
18
18
A 18
17
20
18
21
48373

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 6 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

Cooling
Thermostat
Thermostat Removal
The thermostat can be monitored for proper operation with the CDS G3 tool.
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.

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

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 –

Clamp/Swivel Brackets and Driveshaft Housing
Midsection
Section 5A - Clamp/Swivel Brackets and Driveshaft Housing
Table of Contents
Midsection Specifications...................................................5A-2 Installation.................................................................5A-28
Top Cowl Components...................................................... 5A-4 Upper Mounts.................................................................. 5A-29
Lower Cowl Components...................................................5A-6 Removal....................................................................5A-29
Swivel Bracket and Swivel Pin Components—Non‑SeaPro Installation.................................................................5A-30
....................................................................................... 5A-8 Hose Routing................................................................... 5A-31
Swivel Bracket and Swivel Pin Components—SeaPro....5A-10 Port Side................................................................... 5A-31
Transom Bracket Components........................................ 5A-12 Starboard Side..........................................................5A-32
Adapter Plate Components..............................................5A-14 Driveshaft Housing/Adapter Plate Removal.....................5A-32
Driveshaft Housing Components..................................... 5A-16 Transom/Swivel Bracket.................................................. 5A-33
XL for S/N 2B753570 and Above..............................5A-17
Lower Cowl...................................................................... 5A-18
Disassembly............................................................. 5A-33
Swivel Bracket/Steering Arm Disassembly...............5A-36 5
A
Lower Cowl Removal................................................5A-18 Swivel Bracket/Steering Arm Assembly....................5A-36
Lower Cowl Installation.............................................5A-22 Transom/Swivel Bracket Assembly.......................... 5A-39
Lower Mounts.................................................................. 5A-27 Driveshaft Housing and Swivel Bracket Assembly.......... 5A-41
Removal....................................................................5A-27 Shift Shaft Installation...................................................... 5A-43

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.)

Lower mount flange head bolt threads (M10 x 40) (4)
66 Loctite 242 Threadlocker Upper mount M10 x 40 flange head screw threads 92-809821
Upper pivot pin retaining screw threads
Steering arm assembly
Neutral detent groove and shift shaft spline
95 2-4-C with PTFE Detent ball 92-802859A 1
Shift shaft bushing
Inside and outside diameters of the shift shaft bushing

Notes:

Top Cowl Components
3 6
2
4
48977

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 –

Lower Cowl Components

1
34
21 33
20
4 32
24
26 17 30
27 29
22 25 19
18
12 11
5
23
16 36 10
35
9
3
4 15 15
8 28
7
14 13
6 6
5 31
2
2
37
48363

Lower Cowl Components

Torque
1 1 Top cowl seal
2 1 Chap assembly, port and starboard
3 1 Ingress mounting plate
4 2 Screw (M5 x 8) 8 70.8 –
5 8 Screw (M6 x 25) 10 88.5 –
6 2 Chap support cap
7 1 Hose rigging adapter
8 1 Ingress grommet
9 1 Trim harness grommet
10 1 Lower front cowl
11 1 Top cowl latch
12 2 Screw (M6 x 16) 10 88.5 –
13 1 Port upper mount cover
14 1 Starboard upper mount cover
15 2 Shoulder screw (M6) 10 88.5 –
16 1 Screw (M6 x 85) 10 88.5 –
– 1 Rear panel assembly
17 1 Rear panel
18 2 Latch
19 1 Retainer
20 1 Latch handle
21 1 Icon
22 1 Link
23 1 Pin
24 2 Screw (M6 x 25) 10 88.5 –
25 2 Bushing
26 2 Washer
27 1 Seal
28 1 Trim sensor harness grommet
29 1 Trim switch bezel
30 1 Retainer
31 1 Plug
32 1 Seal
33 1 Fitting
34 1 Tether
35 1 Screw (M6 x 50) 10 88.5 –
36 1 Screw (M6 x 20) 10 88.5 –
37 1 Grommet 10 88.5 –

Swivel Bracket and Swivel Pin Components—Non‑SeaPro

1
2
3
4 36
37
1 4 39
38
5
38
2 6
3 6
18
7
17 10 98
13 16
12
14
11 40
31
29
32
30 32
35 28
26 15
27 25 34 14
19
16
17
18
34 20
21 22
23
24
33
61625

Swivel Bracket and Swivel Pin Components—Non-SeaPro

Torque
1 2 Flange head bolt (M14 x 115)
2 2 Retainer
3 6 Flange head bolt (M10 x 40) 75 – 55.3
4 2 Upper mount
5 1 Steering arm assembly
6 2 Locknut (M14) 122 – 90
7 1 Screw (#10‑16 x 0.600 in.) 1.7 15 –
8 1 Clip
9 1 C‑washer
10 1 Trim position sensor
11 2 Washer
12 2 Screw (#10‑24 x 0.750 in.) 1.7 15 –
13 1 Swivel bracket
14 2 Flange bearing
15 1 Grease fitting
16 2 Bushing
17 2 Seal
18 2 Thrust washer
19 1 Screw 6 53.1 –
20 1 Bottom yoke
21 2 Washer
22 2 Bolt (M14 x 155)
23 2 Lower mount
24 2 Washer
25 2 Washer
26 1 Cable
27 2 Locknut (M14) 122 – 90
28 1 Screw (M6 x 12) 6 53.1 –
29 1 Cable
30 1 Washer
31 1 Retainer
32 2 Upper pivot pin bearing
33 1 Retaining ring
35 1 Screw (M6 x 10) 6 53.1 –
36 1 Link rod assembly
37 1 Screw (0.375‑24 x 1.250) 27 – 20
Brass nut (0.375‑24)—link rod to steering arm 27 – 20
38 2 Tighten until it seats, then back off 1/4
Brass nut (0.375‑24)—link rod to steering cable end
turn
39 2 Washer (0.390 x 0.625 x 0.062)
40 2 Split lockwasher

Swivel Bracket and Swivel Pin Components—SeaPro

1
2
3
4
5 37
38
1 40
5
6 39
39
23 7
4
19
18 9 8
11 10
17
14
13
15
12 41
32
30
31 33
15 29 33
36
28 27 16
26 35
20
17
18
19
35 21
22
24 23
25
34
61626

Swivel Bracket and Swivel Pin Components—SeaPro

Torque
1 2 Flange head bolt (M14 x 115)
2 2 Retainer
3 2 Upper mount washer
5 2 Upper mount
6 1 Steering arm assembly
7 2 Locknut (M14) 122 – 90
8 1 Screw (#10‑16 x 0.600 in.) 1.7 15 –
9 1 Clip
10 1 C‑washer
11 1 Trim position sensor
12 2 Washer
13 2 Screw (#10‑24 x 0.750 in.) 1.7 15 –
14 1 Swivel bracket
15 2 Flange bearing
16 1 Grease fitting
17 2 Bushing
18 2 Seal
19 2 Thrust washer
20 1 Screw 6 53.1 –
21 1 Bottom yoke
22 2 Washer
23 2 Bolt (M14 x 155)
24 2 Lower mount
25 2 Washer
26 2 Washer
27 1 Cable
28 2 Locknut (M14) 122 – 90
29 1 Screw (M6 x 12) 6 53.1 –
30 1 Cable
31 1 Washer
32 1 Retainer
33 2 Upper pivot pin bearing
34 1 Retaining ring
36 1 Screw (M6 x 10) 6 53.1 –
37 1 Link rod assembly
38 1 Screw (0.375‑24 x 1.250) 27 – 20
Brass nut (0.375‑24)—link rod to steering arm 27 – 20
39 2 Tighten until it seats, then back off 1/4
Brass nut (0.375‑24)—link rod to steering cable end
turn
40 2 Washer (0.390 x 0.625 x 0.062)
41 2 Split lockwasher

Transom Bracket Components

29 30
28
27
5
1 6
2
3 7
4
8
4 9 34
11 10
24
25
25
14
16
15
26 34 21 22
21
23
13
12
18
31
17 13
19 20
32
33
12
23
22
48384

Transom Bracket Components

Torque
1 1 Knob
2 1 Pin
3 1 Spring
4 2 Bearing
5 1 Locknut (1.00‑14) (1‑1/4 in. hex) 62 – 45.7
6 1 O‑ring
7 1 Tilt tube
8 1 Transom bracket (port)
9 1 Pin
10 1 Spring
11 1 Tilt lock lever
12 2 Cable assembly
13 2 Screw (M6 x 12) 6 53.1 –
14 1 C‑washer
15 1 Cable clamp
16 1 Transom bracket (starboard)
17 4 Screw (0.500‑20 x 5.00)
18 4 Washer
19 4 Washer
20 4 Nut (0.500‑20)
21 2 Washer
22 2 Screw (M8 x 35) 22 – 16.2
23 2 Washer
24 1 Cable assembly
25 2 Screw (M6 x 10) 6 53.1 –
26 1 Nut (0.875‑14) 68 – 50.2
27 1 Tilt lock lever kit
28 1 Tilt lock bearing
29 1 Pin
30 1 Knob
31 1 Trim limit module
32 1 Cable tie
33 1 Male plug
34 2 Tilt pin bearing

Adapter Plate Components

1
48379


Torque
1 1 Gasket
2 1 O‑ring
3 2 Cowl drain
4 1 Grommet
5 1 Adapter plate
7 3 Flange head bolt (M8 x 40) 27 – 20
8 2 Dowel pin
9 1 Adapter plate seal

Driveshaft Housing Components

Replacement parts will be shown in the 150 FourStroke XL driveshaft housing page in the Electronic Parts Catalog, with a
serial number break shown.

XL for S/N 2B753570 and Above
16
17
18 7 9
20
8 22
1
6 9
21 23
24
10
11
19 12 13
14
2
5 2
2 15
4
2
25
15
4
3
4
4 5
4 5
5
5 26
71423
Torque
Ref. No. Qty. Description
Nm lb‑in. lb‑ft
1 1 Driveshaft housing assembly
2 4 Stud ‑ M12 x 1.75 x 179 30 – 22.1
3 1 Spacer 75 – 55.3
4 5 Washer
5 5 Locknut ‑ M12 60 – 44.2

Torque
Nm lb‑in. lb‑ft
6 1 Cable clamp
7 1 Clip
8 1 Fitting
9 2 Nylon push‑in screw
10 1 O‑ring
11 1 Exhaust cooling fitting
12 1 Washer
13 1 Flange head bolt ‑ M6 x 12 6 53.1 –
14 1 Shift shaft bushing
15 2 Dowel pin 60 – 44.2
16 1 Water tube
17 1 Water tube spacer
18 1 Grommet
19 1 Guide
20 1 Exhaust pipe seal
21 1 Plug
22 1 Speedometer hose assembly
23 2 Lower mount assembly
24 8 Screw ‑ M10 x 1.5 x 40 75 – 55.3
25 1 Screw ‑ M12 x 160 30 – 22.1
26 8 Screw ‑ M10 x 1.5 x 60 75 – 55.3
Lower Cowl
Lower Cowl Removal
! WARNING
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
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.
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
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.
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
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.
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.

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
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.
Lower Mounts
Removal
1. Remove lower cowls. Refer to Lower Cowl Removal.
2. Trim the engine to 20°–30°.
3. Remove the four bolts securing the port lower mount to the driveshaft housing.
4. Remove the port lower mount locknut and bolt.
5. Remove the ground cables.
6. Remove the lower port mount from the driveshaft housing.
Port side
a - Bolt (M14 x 155)
b - Washer
c c - Cable
b
d - Locknut
d e - Washer
f - Lower mount
a g - Flange head bolt (M10 x 40) (4)
e h - Black washer
i - Yoke
f
i g
h
48047
7. Remove the starboard lower mount locknut and bolt.

8. Remove the four bolts securing the starboard lower mount to the driveshaft housing.

9. Remove the starboard lower mount from the driveshaft housing.
Starboard side
a - Bolt (M14 x 155)
h b - Washer
b c - Black washer
g d - Flange head bolt (M10 x
40) (4)
a e - Washer
c f - Locknut
g - Lower mount
h - Speedometer tube
f d
e
48104
Installation
1. Trim the engine to 20°–30°.
2. Ensure the mounting surfaces are clean.
48204
3. Install a washer and a M14 x 155 bolt through the yoke (port side shown).
4. Install the black washer, lower mount, and steel washer.
d Port side
a - Bolt (M14 x 155)
b - Washer
c e c - Black washer
b d - Lower mount
e - Washer
48205
5. Apply Loctite 242 Threadlocker to the threads of the four lower mount flange head bolts.
6. Tighten the bolts to the specified torque.

7. Install the cable (ground wire port side only) onto the bolt.
8. Install a locknut onto the M14 x 155 bolt and tighten the locknut to the specified torque.
IMPORTANT: To achieve the proper clamp load of the upper and lower mounts, apply torque to the M14 locknut not the
bolt head.
Port side
a - Bolt (M14 x 155)
b - Washer
c c - Cable (port side)
b
d - Locknut
d e - Washer
f - Lower mount
a g - Flange head bolt (M10 x 40) (4)
e h - Black washer
i - Yoke
f
i g
h
48047

66 Loctite 242 Threadlocker Lower mount flange head bolt threads (M10 x 40) (4) 92-809821

Lower mount flange head bolt (M10 x 40) 75 – 55.3
Lower mount locknut (M14) 122 – 90
9. Repeat the installation procedure for the starboard side lower mount.
10. Install cowls. Refer to Lower Cowl Installation.
Upper Mounts
Removal
1. Remove the lower cowls. Refer to Lower Cowl Removal.
2. Remove the powerhead mounting screw.
3. Remove the three M10 flange head screws.
4. Remove the M14 locknut and pull the screw through the steering arm.
5. Remove the upper mount from the adapter plate.
a- Powerhead mounting flange head screw (M10 x 60)

b- Flange head screw (M10 x 40) (3)
a c- Flange head screw (M14 x 115)
b d- Upper mount
e- Steering arm
f- Locknut (M14)
c
f
e d
57087

Installation
1. Install the flange head screw through the retainer and upper mount.
NOTE: SeaPro models have a rubber washer between the upper mount and retainer.
2. Align the tab on the retainer with the notch on the upper mount.
a c
d a- Upper mount
b- Notch
b e c- Rubber washer—SeaPro models only
d- Retainer
e- Flange head screw (M14 x 115)
f- Tab
61772
3. Apply Loctite 242 Threadlocker to the threads of the three M10 flange head screws.

4. Align the notch of the upper mount with the tab on the steering arm.
a - Notch
b - Tab
a b
49415
5. Install the three M10 flange head screws through the upper mount and thread them into the adapter plate finger‑tight.
6. Install the M14 x 115 flange head screw through the steering arm. Install the locknut finger‑tight.
IMPORTANT: Ensure that the rubber washer is properly installed (SeaPro models only) and that the retainer tab is
installed into the notch on the upper mount.
Ensure that the steering arm tab is installed into the notch on the upper mount.
7. Tighten the three M10 flange head screws to the specified torque.
8. Tighten the locknut to the specified torque.
IMPORTANT: To achieve the proper clamp load of the upper and lower mounts, apply torque to the M14 locknut not the
screw head.

9. Install the powerhead mounting flange head screw. Tighten the screw to the specified torque.
a b Port side
h c a - Upper mount
b - Rubber washer—SeaPro models only
c - Retainer
d - Flange head screw (M14 x 115)
e - Flange head screw (M10 x 40) (3)
d f - Steering arm
g - Locknut
h - Powerhead mounting flange head screw (M10 x
g 60)
f e
57091


Upper mount flange head screw (M10 x 40) (3) 75 – 55.3
Locknut (M14) 122 – 90
Powerhead mounting flange head screw (M10 x 60) 60 – 44.3
Hose Routing
Port Side
a- Fresh water flush hose

b- Block drain hose
a c- FSM cooling water supply hose
d- Strainer
b
c
d
49260

Starboard Side
g a a- Fuel inlet to filter hose
b- Fuel filter
c- Fuel filter to fuel supply module (FSM) hose
d- Speedometer tube
e- Sprayer hose
b f- FSM
g- Water pump indicator hose
f
d
e
49259
Driveshaft Housing/Adapter Plate Removal

1. Remove the powerhead. Refer to Section 4A ‑ Dressed Powerhead Removal.
2. Remove the gearcase housing. Refer to Section 6A ‑ Gearcase Removal.
3. Remove the shift shaft assembly from the driveshaft housing/adapter plate by pulling straight up on the shaft.
4. Remove the bushing from the driveshaft housing.
a
a - Shift shaft assembly
b b - Bushing
48221
5. Remove the locknuts securing each lower mount to the bottom yoke.
6. Remove the locknuts securing each upper mount to the steering arm.

7. Remove the screw securing the cables to the driveshaft housing. Remove the cable to the lower mount.
a
a
a a
c c 48222
a - Locknut (M14)
b - Screw (M6 x 10)
c - Flat washer
8. Push the bolts partially through the port and starboard upper mounts.
9. Pull the driveshaft housing/adapter plate away from the swivel bracket assembly.
a - Upper mount bolt

b - Swivel bracket assembly
48223
Transom/Swivel Bracket
Disassembly
1. Trim to the full up position. Engage the tilt lock lever.
2. Remove the J‑clip securing the trim position sensor harness.

3. Remove the two screws securing the trim position sensor to the port transom bracket. Remove the trim position sensor.
a - Trim position sensor

b - Trim position sensor
mounting screw (2)
a c - Tilt lock lever
d - Screw (#10 x 5/8)
and J‑clip
d
b
c
61744
4. Remove the upper pivot pin retaining screw from the power trim cylinder rod eye.
a - Upper pivot pin retaining screw (5/16 in.

special)
b - Rod eye
48277
5. Remove the rod eye pin. Retract the power trim cylinder rod.
NOTE: The ground cable and trim harness do not have to be removed if only removing the swivel bracket.
6. Remove the screws securing the ground cable and trim harness retainer.

7. Remove the screw and J‑clip securing the trim harness to the starboard transom bracket.
e f
c
b
c
d b
48278
a- Trim harness
b- Ground cable
c- Screw (M6 x 12)
d- Upper pivot pin
e- Trim harness retainer
f- Screw (M6 x 12) and J‑clip
8. Remove the 1‑1/4 in. hex nut from the tilt tube.
9. Support the swivel bracket while removing the tilt tube from the transom bracket/swivel bracket assembly.
10. Remove the swivel bracket and washers.
b c a- Starboard transom bracket

b- Swivel bracket
a d c- Steering arm assembly
d- Port transom bracket
e- Tilt tube
f- 1‑1/4 in. hex locknut (0.875‑14)
g- 1‑3/8 in. hex locknut (1.000‑14)
h- Washer
e
g
f h h 48279

Swivel Bracket/Steering Arm Disassembly

1. Remove the retaining ring on the bottom of the steering arm assembly.
a- Swivel bracket
b- Bottom yoke
c- Retaining ring
d- Steering arm assembly
a
c
b
d
48343
2. Remove the steering arm assembly from the swivel bracket.

3. Remove the bushings and seals from the top and bottom of the swivel bracket.
4. Do not remove the upper pivot pin bearings unless damaged.
5. Remove old grease from the swivel bracket bore and clean the bore.
6. Inspect the tilt tube bushings in each end of the swivel bracket. Replace if required.
a
e a- Seal
b- Swivel bushing
d b c- Swivel bracket
c d- Upper pivot pin flange bearing
e- Upper pivot pin split journal bearing
f- Tilt tube pivot bushing
f e
d
b
a 62017
Swivel Bracket/Steering Arm Assembly

1. Install a new bushing and seal, spring side up (out), in the top of the swivel bracket.

NOTE: The white dot on the seal indicates the spring side.
a a - Swivel bracket
b
b - Seal
c - Bushing
48335
2. Install a new bushing and seal, spring side down (out), in the bottom of the swivel bracket.
a - Swivel bracket
b - Seal
c - Bushing
a
48332
3. Install the thrust washer on the steering arm assembly.
a - Steering arm assembly

b - Thrust washer
a
48333
4. Install the steering arm assembly into the swivel bracket.

5. Install the thrust washer over the steering arm assembly.
a - Swivel bracket
b - Thrust washer
c - Steering arm assembly
a
b
c
48334
6. Align the bottom yoke mount with the upper mount on the steering arm assembly and assemble the bottom yoke onto the
steering arm assembly.
7. Using a suitable mandrel, install the retaining ring in the groove on the steering arm assembly.
a- Swivel bracket
b- Bottom yoke
c- Retaining ring
d- Steering arm assembly
a
c
b
d
48343
8. Lubricate the steering arm assembly through the grease fitting in the swivel bracket.

95 2-4-C with PTFE Steering arm assembly 92-802859A 1
a - Grease fitting
49422


95 2-4-C with PTFE Steering arm assembly 92-802859A 1
Transom/Swivel Bracket Assembly

1. Assemble the swivel bracket/steering arm assembly and flat washers between the transom brackets.
2. Insert the tilt tube through the transom brackets and the swivel brackets.
3. Install and tighten the tilt tube locknuts in sequence:
a. Thread the large locknut onto the starboard end of the tilt tube until it bottoms on the shoulder.
b. Tighten the large locknut to the specified torque.
c. Thread the small locknut onto the port end of the tilt tube.
d. Tighten the small locknut to the specified torque.
b c a- Starboard transom bracket

b- Swivel bracket
a d c- Steering arm assembly
d- Port transom bracket
e- Tilt tube
f- Tilt tube locknut 1‑1/4 in. hex (0.875‑14)
g- Tilt tube locknut 1‑3/8 in. hex (1.0‑14)
h- Washer
e
g
f h h 48279

Tilt tube locknut (1‑3/8 in. hex) 62 – 45.7
Tilt tube locknut (1‑1/4 in. hex) 68 – 50.2
4. Ensure the bearings are installed in the upper pivot pin bore.
a. For engines equipped with flange bearings, ensure the flange is facing inward, as shown.
b. For engines equipped with split journal bearings without flanges, install the bearings until the edge of the bearing is
flush with the inside face of the pivot pin bore.
a a - Flange bearing
b - Split journal bearing
62021
5. Align the power trim cylinder rod eye and the swivel bracket cross holes.
NOTE: The hole in the rod eye faces aft.

6. Insert the upper pivot pin, with the slotted end inserted first, through the swivel bracket and power trim cylinder rod eye.
IMPORTANT: The slotted end of the pivot pin faces starboard.
a a- Upper pivot pin (slot is in line with cross hole)

b b- Hole in rod eye (faces aft)
c- Upper pivot pin retaining screw
c
d- Tilt ram end
d
48336
7. Insert a punch into the trim cylinder rod eye to align the cross hole in the upper pivot pin.
8. Apply Loctite 242 Threadlocker to the threads of the upper pivot pin retaining screw.
9. Install the upper pivot pin retaining screw into the upper pivot pin and trim cylinder rod eye. Tighten the upper pivot pin
retaining screw to the specified torque.
a - Upper pivot pin retaining

c screw (5/16 in. special)
b - Trim cylinder rod eye
d c - Upper pivot pin
d - Slotted end of pivot pin
b
48758

66 Loctite 242 Threadlocker Upper pivot pin retaining screw threads 92-809821

Upper pivot pin retaining screw 32 – 23.6
10. Install the trim position sensor with the potting side out, as shown, and secure with two screws. Tighten to the specified
torque.

IMPORTANT: The trim position sensor must be installed with the potting side facing out. Newer design 2 sensors have
locating pins to ensure proper installation.
a - Trim position sensor

b - Trim position sensor
e mounting screw (2)
c - Tilt lock lever
a
d - Screw (#10 x 5/8)
and J‑clip
e - Locating pins on
design 2 trim position
d sensor
b
c
61743

Trim position sensor mounting screws 1.7 15 –
11. Ensure that the trim harness and ground cable are routed and secured as shown.
e f
c
b
c
d b
48278
a- Trim harness
b- Ground cable
c- Screw (M6 x 12)
d- Upper pivot pin
e- Trim harness retainer
f- Screw (M6 x 12) and J‑clip
Driveshaft Housing and Swivel Bracket Assembly

1. Tilt the midsection to a 15–20° angle.
2. Install two M14 x 155 bolts and washers through the bottom yoke.
3. Install a black washer onto each lower mount bolt.
4. Install a M14 x 115 flange head bolt and retainer through each upper mount.
5. Assemble the driveshaft housing/adapter plate to the steering bracket and the bottom yoke by sliding the lower mounts
over the lower mounting bolts while pushing the upper mounting bolts through the steering arm.

IMPORTANT: Ensure that the notch on the upper mount aligns with the tab on the steering arm.
NOTE: SeaPro models have a rubber washer between the upper mount and retainer.
b a- Retainer
a b- Flange head bolt (M14 x 115)
c- Rubber washer—SeaPro models only
c d- Black washer
e- Flat washer
f- Bolt (M14 x 155)
d
e
f
61805
6. Install a locknut on each upper mounting bolt. Tighten locknuts to the specified torque.
7. Install a flat washer onto each lower mounting bolt.
8. Install the cable onto the port lower mounting bolt.
9. Install a locknut on each lower mounting bolt. Tighten locknuts to the specified torque.
10. Secure the two cables on the port side with a screw.
a
a
a a
c c 48222
Port side Starboard side

a - Locknut (M14)
b - Screw (M6 x 10)
c - Flat washer

Locknuts (M14) (4) 122 – 90
Cable screw 6 53.1 –

Shift Shaft Installation

The shift shaft assembly has a neutral position detent. The shift shaft has a machined groove that the detent ball drops into
when in neutral. A slight resistance is felt when shifting into and out of neutral to the forward or reverse gears.

b - Detent notch
c - Neutral detent assembly
a
b
49567
1. Ensure that the gear shift is in neutral.

2. Apply a light coat of 2‑4‑C with PTFE to the neutral detent groove and shift shaft splines.
a a - Neutral detent groove

b - Shift shaft splines
95
b 13068

95 2-4-C with PTFE Neutral detent groove and shift shaft spline 92-802859A 1
3. Inspect the detent ball for signs of galling or metal debris. Ensure that the detent ball operates freely. If signs of wear
appear, inspect the shift shaft.
4. Clean the detent assembly and lubricate the detent ball end with 2‑4‑C with PTFE.
a a - Neutral detent assembly

b - Detent ball
b
49568

95 2-4-C with PTFE Detent ball 92-802859A 1

5. Install a bushing onto the shift shaft. Apply 2‑4‑C with PTFE to the bushing.
a - Bushing
b - Shift shaft
49569

95 2-4-C with PTFE Shift shaft bushing 92-802859A 1
6. Install the detent assembly into the adapter plate. Tighten the detent assembly to the specified torque.
49554

Shift detent assembly 20 177 –
7. Lubricate the inside and outside diameters of the shift shaft bushing with 2‑4‑C with PTFE.
8. Push or lightly tap the shift shaft bushing into the bore in the adapter plate.
a - Shift shaft bushing
49647


95 2-4-C with PTFE Inside and outside diameters of the shift shaft bushing 92-802859A 1
9. Install the shift shaft through the bushing in the adapter plate.
a
b b - Bushing
48221

Notes:

Adapter Plate and Driveshaft Housing
Midsection
Section 5B - Adapter Plate and Driveshaft Housing
Table of Contents
Adapter Plate Components................................................5B-4 Installation.................................................................5B-14
Oil Sump Components.......................................................5B-6 Disassembly.....................................................................5B-16
Driveshaft Housing Components....................................... 5B-8 Driveshaft Housing/Adapter Plate Disassembly....... 5B-16
XL for S/N 2B753570 and Above................................5B-9 Adapter Plate/Oil Sump............................................ 5B-17
Exhaust Components.......................................................5B-12 Exhaust Tube............................................................5B-19
Preparing Outboard for Adapter Plate Disassembly........ 5B-14 Assembly......................................................................... 5B-22
Fuel Supply Module (FSM).............................................. 5B-14 Adapter Plate/Oil Sump............................................ 5B-22
Removal....................................................................5B-14 Driveshaft Housing/Adapter Plate Assembly............ 5B-25
5
B


FSM mounting bolt
Flange head bolt (M6 x 16) (2)
66 Loctite 242 Threadlocker Flange head bolt (M6 x 40) (8) 92-809821
Adapter plate mounting bolts (M10 x 60 flange head) (8)
Exhaust tube mounting bolt (M6 x 25 flange head)

Notes:


1
48379


Torque
1 1 Gasket
2 1 O‑ring
3 2 Cowl drain
4 1 Grommet
5 1 Adapter plate
7 3 Flange head bolt (M8 x 40) 27 – 20
8 2 Dowel pin
9 1 Adapter plate seal

Oil Sump Components
10
9
8
7
6 5
48957

Oil Sump Components

Torque
1 1 Gasket ‑ driveshaft housing to adapter plate
2 1 Oil cooler
3 1 Gasket
4 1 Oil sump
5 8 Flange head bolt (M6 x 40) 10 88.5 –
6 1 Oil drain valve 15 133 –
7 1 O‑ring
8 1 O‑ring
9 1 O‑ring
10 1 Oil sump seal

Driveshaft Housing Components

Replacement parts will be shown in the 150 FourStroke XL driveshaft housing page in the Electronic Parts Catalog, with a
serial number break shown.

XL for S/N 2B753570 and Above
16
17
18 7 9
20
8 22
1
6 9
21 23
24
10
11
19 12 13
14
2
5 2
2 15
4
2
25
15
4
3
4
4 5
4 5
5
5 26
71423
Torque
Nm lb‑in. lb‑ft
1 1 Driveshaft housing assembly
2 4 Stud ‑ M12 x 1.75 x 179 30 – 22.1
3 1 Spacer 75 – 55.3
4 5 Washer
5 5 Locknut ‑ M12 60 – 44.2

Torque
Nm lb‑in. lb‑ft
6 1 Cable clamp
7 1 Clip
8 1 Fitting
9 2 Nylon push‑in screw
10 1 O‑ring
11 1 Exhaust cooling fitting
12 1 Washer
13 1 Flange head bolt ‑ M6 x 12 6 53.1 –
14 1 Shift shaft bushing
15 2 Dowel pin 60 – 44.2
16 1 Water tube
17 1 Water tube spacer
18 1 Grommet
19 1 Guide
21 1 Plug
22 1 Speedometer hose assembly
23 2 Lower mount assembly
24 8 Screw ‑ M10 x 1.5 x 40 75 – 55.3
25 1 Screw ‑ M12 x 160 30 – 22.1
26 8 Screw ‑ M10 x 1.5 x 60 75 – 55.3

Notes:

Exhaust Components
1
7
5 6 8
20
9
10
16 17
18
19
16
11
12
13
12
13
15
14
48382

Exhaust Components
Torque
1 1 Idle relief muffler
2 1 Idle relief muffler elbow
3 2 Clamp
5 1 Idle relief tube assembly
6 2 O‑ring
7 1 Grommet
8 1 O‑ring
9 1 O‑ring
10 1 Exhaust pipe flange seal
11 1 Exhaust pipe assembly
12 2 Plug (18 mm)
13 2 O‑ring
15 1 Water tube grommet
17 1 Strainer
18 1 Seal

Preparing Outboard for Adapter Plate Disassembly

1. Remove the powerhead. Refer to Section 4A ‑ Dressed Powerhead Removal.
2. Remove the driveshaft housing/adapter plate from the swivel bracket assembly. Refer to Section 5A ‑ Driveshaft
Housing/Adapter Plate Removal.
NOTE: The adapter plate may be removed without removing the driveshaft housing from the swivel bracket assembly.
Remove the through bolts from the upper mounts.
3. Remove the fuel supply module. Refer to Fuel Supply Module (FSM).
Fuel Supply Module (FSM)

Removal
1. Remove the FSM cooling water supply hose to the fuel supply module.
a - Fuel supply module

b - Cable tie
c - FSM cooling water supply hose
b
c
a
48347
2. Remove the bolt securing the fuel supply module to the driveshaft housing.
3. Remove the plastic screw securing the FSM hose to the driveshaft housing.
4. Remove the cable tie securing the exhaust cooling hose to the fitting and remove the hose.
5. Pull the FSM out and back to remove.

b - FSM mounting bolt and
washer (M6 x 25 flange
a c head)
c - Plastic screw and clamp
d - Cable tie
48392
Installation
1. Assemble the fuel supply module components as shown.
2. Apply Loctite 242 Threadlocker to the FSM mounting bolt.

3. Secure the FSM to the driveshaft housing with the bolt and washer. Tighten the bolt to the specified torque.
f g c
a- Fuel supply module
g b- FSM retainer grommet
d c- Metal clamp (15.7 mm) (4)
c d- Hose (2)
b e- Fuel filter—design 1 shown
e f- Plastic sleeve
c g- Cable tie (3)
h- Fuel filter to FSM hose
d
i- Plastic screw
c j- Hose clip
a k- FSM mounting bolt (M6 x 25 flange head)
l- Washer
m- Grommet
h n- Bushing
o- Hose to exhaust cooling fitting
l
n k
m
g j
i
o 49106

66 Loctite 242 Threadlocker FSM mounting bolt 92-809821

FSM mounting bolt (M6 x 25 flange head) 6 53.1 –
4. Attach the FSM hose to the driveshaft housing with the clamp and plastic screw.

b - FSM mounting bolt and
washer (M6 x 25 flange
a c head)
c - Plastic screw and clamp
d - Cable tie
48392

5. Install the FSM cooling water supply hose to the fitting. Secure with a cable tie.

b - Cable tie
c - FSM cooling water supply hose
b
c
a
48347
Disassembly
Driveshaft Housing/Adapter Plate Disassembly
NOTE: The adapter plate may be removed without removing the driveshaft housing/adapter plate from the swivel bracket
assembly. Remove the through bolts from the upper mounts.
1. Remove the eight M10 x 60 flange head bolts securing the adapter plate to the driveshaft housing.
2. Remove the M6 x 25 flange head bolt securing the exhaust tube to the adapter plate.
NOTE: The strainer was removed during the powerhead removal.
Starboard
a - Flange head bolt (M10 x 60) (4)
a
a
a 48345
Port
b - Flange head bolt (M6 x 25)
a a 48346

3. Remove the speedometer tube from the barbed fitting on the driveshaft housing.
4. Remove the speedometer tube from the adapter plate.
5. Remove the adapter plate from the driveshaft housing.
a a- Speedometer tube
b- Adapter plate
b c- Driveshaft housing
d- Dowel pin (2)
d d
c
48348
NOTE: If the dowel pins remain in the driveshaft housing, remove and install into the adapter plate.
a a - Dowel pin (2)
49296
Adapter Plate/Oil Sump

j k Top
a b a - Dowel pin (2)
i
b - Adapter plate seal
h
c - O‑ring
f c d - Water pump indicator fitting
e - Idle relief elbow
f - Cowl drain (2)
g g - Fuel supply module seal
I
h - Cooling water supply hose to FSM
i - Grommet
j - Thermostat dump fitting hole
f k - Gasket (powerhead base)
l - Access hole to oil sump
e
a
d 48391

Bottom
b
c a a - Flange head bolt (M6 x 16)
b - Water pump indicator fitting
c - Idle relief muffler fitting
d d - Flange head bolt (M6 x 16)
e - Dowel pin (2)
f - Block drain fitting
e
f
48390
Disassembly
1. Remove the eight flange head bolts securing the oil sump to the adapter plate.
2. Remove the oil sump.
3. Remove the oil sump seal and oil drain valve.
b
c
a d
e
f 48349
a- Flange head bolt (M6 x 40) (8)

b- Adapter plate
c- Oil cooler
d- Oil sump
e- Oil sump seal
f- Oil drain valve

4. Inspect the oil drain valve O‑rings. Replace if necessary.
48459
5. Remove the gaskets and oil cooler.
a - Adapter plate
a b - Gasket (adapter plate to oil cooler/driveshaft
housing)
b c - Oil cooler
d - Gasket (oil cooler to oil sump)
d 48389
Exhaust Tube
Removal
1. Remove the gearcase. Refer to Section 6A or 6B ‑ Gearcase Removal.
2. Remove the water tube coupler and guide.
a a - Water tube
b - Guide
c - Coupler
48394

3. Remove the exhaust tube from the driveshaft housing.
48393
4. Remove the two grommets from the driveshaft housing.
a - Water tube grommet

b - Exhaust tube grommet
b
a
48395

1. Remove and replace both exhaust tube O‑rings.
2. Inspect the exhaust tube seals and replace if damaged.
3. Remove the water tube and grommet.

4. Inspect the water tube grommet and replace if damaged.
e f
a b c d
48445
a- O‑ring
b- O‑ring
c- Flange seal
d- Seal
e- Grommet
f- Water tube
NOTE: The strainer was removed during powerhead removal.

5. Inspect the strainer for debris.
6. Inspect the seal.
a a - Block drain hose (to adapter plate)

b - Seal
b c - Strainer
48446
7. Inspect the water tube and grommet.
a a - Water tube
b b - Grommet
48447
Assembly
1. Install the O‑rings onto the exhaust tube.

2. Install the flange seal and seal onto the exhaust tube as shown.
a b c d
e 49268
a- O‑ring
b- O‑ring
c- Flange seal
d- Seal
e- Locating protrusions on seal
f- Notch on flange seal
3. Install the grommet into the exhaust tube.

4. Install the water tube into the grommet.
b
a
c
49269
a - Grommet
b - Water tube
c - Strainer
NOTE: The strainer is installed after the powerhead is installed.
Assembly
Adapter Plate/Oil Sump
1. If the two dowel pins are not installed in the top of the adapter plate, remove them from the powerhead and install into the
adapter plate.
2. If the two dowel pins are not installed in the bottom of the adapter plate, remove them from the driveshaft housing and
install into the adapter plate. The dowel pins ensure the alignment of the components.

3. Inspect the O‑ring on the water pump indicator fitting. Replace if damaged.
4. Install the fitting into the hole on the adapter plate.
5. Apply Loctite 242 Threadlocker to the bolt securing the water pump indicator fitting.
6. Tighten the bolt to the specified torque.
7. Inspect the O‑rings on the idle relief muffler fitting. Replace if damaged.
8. Install the fitting into the hole on the adapter plate.
9. Apply Loctite 242 Threadlocker to the bolt securing the idle relief muffler fitting.
10. Tighten the bolt to the specified torque.
j k Top
a b a - Dowel pin (2)
i
b - Adapter plate seal
h
c - O‑ring
f c d - Water pump indicator fitting
e - Idle relief elbow
f - Cowl drain (2)
g g - FSM seal
I
h - Cooling water supply hose to FSM
i - Grommet
j - Thermostat dump fitting hole
f k - Gasket (powerhead base)
l - Access hole to oil sump
e
a
d 48391
Bottom
b
c a a - Flange head bolt (M6 x 16)
b - Water pump indicator fitting
c - Idle relief muffler fitting
d d - Flange head bolt (M6 x 16)
e - Dowel pin (2)
f - Block drain fitting
e
f
48390


Flange head bolt (M6 x 16) (2) 6 53.1 –
11. Clean the mating surfaces of the adapter plate, oil cooler, and oil sump.

12. Install the adapter plate to oil cooler gasket, oil cooler, and oil cooler to oil sump gasket.
a - Adapter plate
a b - Gasket (adapter plate to oil cooler/driveshaft
housing)
b c - Oil cooler
d - Gasket (oil cooler to oil sump)
d 48389
13. Apply Loctite 242 Threadlocker to the eight oil sump bolts.
14. Install the oil sump.
15. Tighten the bolts in sequence to the specified torque.
16. Install the oil sump seal and oil drain valve. Tighten the oil drain valve to the specified torque.
b
c
a d
e
f 48349
a- Flange head bolt (M6 x 40) (8)

b- Adapter plate
c- Oil cooler
d- Oil sump
e- Oil sump seal
f- Oil drain valve

8
6
3
4 2 48505
Torque sequence


Flange head bolt (M6 x 40) (8) 10 88.5 –
Oil drain valve 15 132.7 –
Driveshaft Housing/Adapter Plate Assembly

1. Assemble the adapter plate components. Refer to Adapter Plate/Oil Sump.
2. Assemble the exhaust tube components to the driveshaft housing. Refer to Exhaust Tube.
3. Install the adapter plate onto the driveshaft housing.
a. Guide the adapter plate/oil sump over the exhaust tube while carefully guiding the oil drain valve through the opening
in the driveshaft housing.
b. Align the adapter plate dowel pins with the holes on the driveshaft housing.
c. Assemble the fuel supply module to the driveshaft housing. Refer to Fuel Supply Module (FSM).
d. Attach the hose to the FSM. Secure with a cable tie.
e. Install the powerhead gasket onto the adapter plate.
f. Install the speedometer tube through the grommet in the adapter plate.
g. Install the speedometer tube end onto the barbed fitting on the driveshaft housing.
h. Install the adapter plate seal.
a a- Exhaust tube
h b- Adapter plate
c- Adapter plate seal
d- Driveshaft housing
e- Speedometer tube
g b f- Fuel supply module (FSM)
g- Hose
h- Gasket (adapter plate to
f powerhead)
c
e
d
48452
4. Apply Loctite 242 Threadlocker to the eight adapter plate mounting bolts.

5. Apply Loctite 242 Threadlocker to the M6 x 25 flange head bolt.
6. Install the adapter plate mounting bolts. Tighten the bolts in sequence to the specified torque.
7. Secure the exhaust tube to the adapter plate with the M6 x 25 flange head bolt. Do not tighten the bolt at this time.
Starboard
a
a
a 48345
Port
b - Flange head bolt (M6 x 25)
a a 48346
4 3
2
7
5 6 48504
Torque sequence

66 Loctite 242 Threadlocker Adapter plate mounting bolts (M10 x 60 flange head) (8) 92-809821
66 Loctite 242 Threadlocker Exhaust tube mounting bolt (M6 x 25 flange head) 92-809821

Adapter plate mounting bolt (M10 x 60 flange head) (8) 60 – 44.2

8. Install the water tube guide and coupler onto the water tube.
a a - Water tube
b - Guide
c - Coupler
48394

Notes:

Power Trim
Midsection
Section 5C - Power Trim
Table of Contents
Power Trim Specifications................................................. 5C-2 Manual Release Valve..............................................5C-48
Power Trim Assembly Components—Design 1.................5C-4 Pressure‑Operated (PO) Check Valve..................... 5C-49
Power Trim Assembly Components—Design 2.................5C-6 Pressure Relief Valves............................................. 5C-49
Power Trim Components—Design 1................................. 5C-8 Thermal Relief Valve................................................ 5C-50
Power Trim Components—Design 2............................... 5C-10 Trim Cylinder and Shock Piston............................... 5C-50
Power Trim General Information......................................5C-13 Memory Piston Removal.......................................... 5C-51
General Information..................................................5C-13 Power Trim Disassembly—Design 2............................... 5C-52
Power Trim Operation.............................................. 5C-13 Draining the Power Trim Fluid.................................. 5C-52
Trailering Boat/Outboard ......................................... 5C-13 Lower Pivot Bushings............................................... 5C-52
Manual Tilting........................................................... 5C-14
Purging Power Trim System.....................................5C-14
Filter..........................................................................5C-52
Power Trim Pump and Motor....................................5C-54 5
C
Power Trim Flow Diagrams—Design 1 and 2..................5C-16 Reservoir Protection Valve....................................... 5C-55
Trim/Tilt—Up Circuit................................................. 5C-16 Manual Release Valve..............................................5C-55
Trim/Tilt—Down Circuit.............................................5C-18 Pressure‑Operated (PO) Check Valve..................... 5C-56
Maximum Tilt............................................................ 5C-20 Pressure Relief Valves............................................. 5C-56
Maximum Trim Down................................................5C-22 Trim Cylinder and Shock Piston............................... 5C-57
Shock Function Up................................................... 5C-24 Memory Piston Removal.......................................... 5C-59
Shock Function Return............................................. 5C-26 Power Trim Cleaning, Inspection, and Repair................. 5C-59
Manual Tilt................................................................ 5C-28 Nonserviceable Components................................... 5C-60
Reverse Operation................................................... 5C-29 Power Trim Assembly—Design 1.................................... 5C-62
General Hydraulic Service Recommendations................ 5C-29 O‑Ring and Seal Placement..................................... 5C-62
Seals.........................................................................5C-29 Pressure‑Operated (PO) Check Valve..................... 5C-65
Power Trim System Pressure Tests................................ 5C-30 Up and Down Pressure Relief Valves...................... 5C-66
Up Pressure Check.................................................. 5C-30 Up Thermal Relief Valve...........................................5C-66
Down Pressure Check..............................................5C-31 Trim Pump and Motor...............................................5C-67
Trim System Hydraulic Troubleshooting..........................5C-32 Trim Cylinder............................................................ 5C-68
Troubleshooting........................................................5C-32 Lower Pivot Bushings............................................... 5C-69
Power Tilt Leakage Test Procedure......................... 5C-32 Power Trim Assembly—Design 2.................................... 5C-72
Hydraulic System Troubleshooting...........................5C-33 O‑Ring, Washer, and Seal Placement......................5C-72
Electrical System Troubleshooting.................................. 5C-34 Pressure‑Operated (PO) Check Valve..................... 5C-74
Wire Color Code Abbreviations................................ 5C-34 Up and Down Pressure Relief Valves...................... 5C-74
Before Troubleshooting............................................ 5C-34 Reservoir Protection Valve....................................... 5C-76
Trim Circuit............................................................... 5C-34 Manual Release Valve..............................................5C-76
Power Trim Relay Test Procedure........................... 5C-35 Filter..........................................................................5C-77
Power Trim Relay Removal and Installation.............5C-36 Trim Pump and Motor...............................................5C-77
Power Trim Electrical Circuit Diagram...................... 5C-39 Trim Cylinder............................................................ 5C-79
Troubleshooting the Power Trim Electrical System..5C-39 Lower Pivot Bushings............................................... 5C-80
Power Trim System Removal.......................................... 5C-42 Power Trim System Installation....................................... 5C-80
Power Trim Disassembly—Design 1............................... 5C-45 Trim Sensor..................................................................... 5C-85
Draining the Power Trim Fluid.................................. 5C-45 General Information..................................................5C-85
Lower Pivot Bushings............................................... 5C-46 Trim Sensor Down Adaptation..................................5C-85
Filter..........................................................................5C-46 Trim Sensor Down Adaptation Reset....................... 5C-85
Power Trim Pump and Motor....................................5C-47

Power Trim

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

28 Dexron III Automatic O-rings Obtain Locally
Inside diameter of oil seals
95 2-4-C with PTFE Lower pivot bushings 92-802859A 1
Lower pivot pin
O-rings
Power trim reservoir
Power Trim and Steering Power trim system reservoir and O-ring lubrication
114 92-858074K01
Fluid Power trim O-rings
Power trim system
O-rings and outer surfaces of valve components
Special Tools
Pressure Adapter Fitting ‑ Up 8M0061797
Install in place of the manual release valve to measure the up pressure in the
power trim system.
48707
Power Trim Test Gauge Kit 91‑52915A6
Tests circuit pressures for various trim pumps.
3753
Pressure Adapter Fitting ‑ Down 8M0054662
Install in place of the manual release valve to measure the down pressure in the
power trim system.
48708

V Hz
H z TEMP
mA
A
mV IG
OFF IP
TEMP
A mA COM V Hz
4516

Power Trim
Expanding Rod Snap‑On CG41‑11
Aids in the removal of the spool from the power trim pump.
8753
Collet Snap‑On CG41‑14
Aids in the removal of the spool from the power trim pump.
8754
Trim Cylinder End Cap Tool 91‑821709T
Allows easy removal of the trim cylinder end caps. Required if tilt limit spacers
are to be installed or if the trim in limit spacer is to be removed (to allow
additional trim in range).
10691
Lockring Pliers Snap‑On SRP'4
Aids in the removal of lock rings and the memory piston.
4799
Spanner Wrench 91‑ 74951
Removes and installs trim cylinder end caps.
8775
CDS G3 Interface Kit 8M0153916
CDS G3 License Key, Interface, Adapter, and Harness
69585

Power Trim
Power Trim Assembly Components—Design 1

2
3
4
48948

Power Trim

Torque
1 1 Power trim assembly
2 1 Upper pivot pin
3 2 Bushing
4 1 Anode
5 2 Washer
6 2 Screw (M6 x 25) 8 70.8 –
7 1 Lower pivot pin

Power Trim

2
3
4
70556

Power Trim

Torque
1 1 Power trim assembly
2 1 Upper pivot pin
3 2 Bushing
4 1 Anode
5 2 Washer
6 2 Screw (M6 x 25) 8 70.8 –
7 1 Lower pivot pin

Power Trim
Power Trim Components—Design 1
21
1
20
19
3
2
20
5
17
7
18
6
8
9
10 11
12 13
16
15
14
11 48556

Power Trim

Torque
1 1 Electric motor
2 1 O‑ring
3 2 Bolt 9 79.6 –
4 2 Washer
5 1 Drive coupling
6 1 Pump
7 2 Bolt 8 70.8 –
8 2 O‑ring
9 2 O‑ring
10 1 Dowel pin
11 1 Pressure‑operated valve kit 14 124 –
12 1 Filter kit
13 1 Relief valve (2) and thermal relief valve kit 4 35.4 –
14 1 Manual release valve kit
15 1 Reservoir cap kit 2.5 22.1 –
16 1 Power trim body
17 1 Memory piston
18 1 O‑ring
19 1 Trim rod assembly 100 – 73.7
20 2 O‑ring
21 1 Screw (5/16‑24 x 0.5) 32 – 23.6

Power Trim

23
10 22
12 18 24
26
17
13 25
14 26
4
16
15
27
33
11 29
29
19
7
20
8 28
21
5 2 30
11
9
32
6 1
31
69
70
34 35 74
2 17
71
72
73
75 3
2
50 61
52 17
49 2 66 65
51 48 60 67
59 68
58
57 2
38
47 45
48 40
49 42 37
46 61 41
50 60 43
17 2 36
56 63 39
55 2 44
62
54 65 75
53 64
70558

Power Trim

Torque
1 1 Manifold
2 8 Bolt plug 6.8 60 –
3 1 Bolt plug 13.3 118 –
4 1 Trim rod assembly
5 1 Rod guide end cap 205 – 151.2
6 1 Bushing
7 2 Water seal
8 2 Cushion
9 2 O‑ring
10 1 Piston 185 – 136.4
11 2 O‑ring
12 1 O‑ring
13 7 Ball
14 1 Check valve seat
15 6 Valve spring
16 1 Valve spring
17 1 Ball
18 1 Spring pin
19 1 Spring stopper
20 2 Bolt 5.5 49 –
21 1 Free piston
22 1 Motor
23 1 Band
24 1 Label
25 1 Caution Label
26 2 Hex cap screw 4.5 40 –
27 1 O‑ring
28 1 Pump assembly
29 2 Hex head screw 4.5 40 –
30 2 O‑ring
31 1 Filter
32 1 Filter spring
33 1 Coupler
34 1 Reservoir Cap 2.4 21.2 –
35 1 O‑ring
36 1 Manual valve 3.2 28.3 –
37 1 O‑ring
38 2 Ball
39 2 Spring seat
40 1 Spring
41 1 Valve seat
42 1 Cushion
43 1 Backup ring
44 1 Internal circlip
45 1 Seal washer
46 1 Centering plate

Power Trim
Torque
47 1 Spring guide seat
48 2 Valve spring
49 2 Diaphragm cup
50 2 O‑ring
51 1 Spring guide
52 1 Centering plate
53 1 Sleeve
54 1 O‑ring
55 1 Spool
56 1 Backup ring
57 1 Plug bolt 41 – 30.2
58 1 O‑ring
59 1 O‑ring
60 2 Valve seat
61 2 O‑ring
62 1 Spring
63 1 Spring guide
64 1 Plug 7.7 68.1 –
65 2 O‑ring
66 1 Spring
67 1 Spring guide
68 1 Plug bolt 5.5 48.6 –
69 1 Plug bolt 6.4 56.6 –
70 1 O‑ring
71 1 Valve seat
72 1 Relief spring
73 1 Housing
74 1 O‑ring
75 2 Guide bushing

Power Trim
Power Trim General Information

General Information
The power trim system consists of an electric motor, pressurized fluid reservoir, pump, and trim cylinder.
Trim outboard through entire trim and tilt range several times to remove any air from the system.
The remote control or trim panel is equipped with a switch that is used for trimming the outboard up or down, for tilting the
outboard for shallow water operation at slow speeds, or for trailering. The outboard can be trimmed up or down while engine is
under power or when engine is not running.
Power Trim Operation

With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of
the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an
improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some
potential control hazards.
The most significant control hazard is a pull or torque that can be felt on the steering wheel or tiller handle. This steering torque
results from the outboard being trimmed so the propeller shaft is not parallel to the water surface.
! WARNING
Trimming the outboard beyond a neutral steering condition may result in a pull on the steering wheel or tiller handle and loss
of boat control. Maintain control of the boat if trimming beyond a neutral steering condition.
Consider the following lists carefully.

1. Trimming in or down can:
• Lower the bow
• Result in quicker planing off, especially with a heavy load or a stern heavy boat
• Generally improve the ride in choppy water
• Increase steering torque or pull to the right (with the normal right‑hand rotation propeller)
• In excess, can lower the bow of some boats to a point where they begin to plow with their bow in the water while on
plane. This can result in an unexpected turn in either direction (called bow steering or oversteering) if any turn is
attempted, or if a significant wave is encountered.
2. Trimming out or up can:
• Lift the bow higher out of the water
• Generally increase top speed
• Increase clearance over submerged objects or a shallow bottom
• Increase steering torque or pull to the left at a normal installation height (with the normal right‑hand rotation propeller)
• In excess, can cause boat porpoising (bouncing) or propeller ventilation
• Cause engine overheating if any cooling water intake holes are above the waterline
Trailering Boat/Outboard
Trailer your boat with the outboard tilted down in a vertical operating position.
If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer
to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways, and trailer
bouncing.
21997

Power Trim
IMPORTANT: Do not rely on the power trim/tilt system or tilt support lever to maintain proper ground clearance for trailering.
The outboard tilt support lever is not intended to support the outboard for trailering.
Shift the outboard to forward gear. This prevents the propeller from spinning freely.
Manual Tilting
If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.
IMPORTANT: The engine/gearcase will drop (tilt down) when the manual release valve is opened.
NOTE: The manual tilt release valve must be tightened before operating the outboard to prevent the outboard from tilting up
during reverse operation.
IMPORTANT: Do not operate the outboard in either the up or down position with the manual tilt valve open. Damage to the
O‑rings may occur.
Turn out the manual tilt release valve slowly three turns counterclockwise. This allows manual tilting of the outboard. Tilt the
outboard to the desired position and tighten the manual tilt release valve.
22362
Purging Power Trim System

IMPORTANT: The fill cap with O‑ring must be tightened securely before operating the power trim system.
IMPORTANT: Operate the power trim system in short spurts until the hydraulic pump is primed and the trim cylinders move.
• Cycle the outboard through the entire trim/tilt range four times.
• To check for presence of air in the system, extend cylinders slightly and push down on outboard. If the trim rams retract
more than 3 mm (0.125 in.), air is present. Cycle trim system again and repeat this step.
• Check fluid level. Refer to Section 1B ‑ Checking Power Trim Fluid.

Power Trim
Notes:

Power Trim
Power Trim Flow Diagrams—Design 1 and 2

Trim/Tilt—Up Circuit
s
r
c b
v
e d
q f
p
j g
o
h
n Ii
k
w t
62055

Power Trim
a- Electric motor m- Cylinder
b- Reservoir oil n- Memory piston
c- Oil pump o- Shock piston
d- Down circuit suction ball p- Impact relief valve
e- Up circuit suction ball q- Shock return valve
f- Down circuit pressure relief valve r- End cap
g- Up circuit pressure relief valve s- Trim rod
h- Up circuit pressure‑operated check valve t- High‑pressure oil
i- Shuttle spool u- Low‑pressure oil
j- Down circuit pressure‑operated check valve v- Down fluid cavity
k- Thermal relief valve w- Up fluid cavity
l- Manual release valve
When the trim switch is activated in the up position, the electric motor begins to rotate the pump gears, and the oil pump draws
a small amount of oil through the up circuit suction port. The oil pump gear rotation forces oil into the passages for the up
circuit. Oil under pressure slides the shuttle spool against the down circuit pressure‑operated valve. The shuttle spool
mechanically opens the down circuit pressure‑operated valve, allowing oil from the down fluid cavity of the trim cylinder to flow
into the oil pump. This oil returning from the down fluid cavity supplies most of the oil required for the up circuit.
Oil in the up circuit is blocked from returning into the reservoir by the ball inside the down circuit suction port. The pressure of
the oil forces the up circuit pressure‑operated valve to open, allowing the oil to enter the passages inside the manifold leading
to the trim cylinder up fluid cavity. Oil is blocked from all other passages by the closed manual release valve. Oil under pressure
enters the trim cylinder below the memory piston. With an increasing amount of oil entering the cylinder, the memory and shock
pistons force the trim rod up and out, raising the outboard engine. Oil on the top of the shock piston exits through a passage
running down along the side of the cylinder and enters the manifold passages. The oil is drawn back into the pump through the
open down circuit pressure‑operated valve and enters the pump as supply for the up circuit.
The trim cylinder positions the outboard at the desired trim angle in the 20º maximum trim range. The system will not allow the
outboard to be trimmed above the 20º trim range as long as the engine is above approximately 2000 RPM.

Power Trim
Trim/Tilt—Down Circuit
s
r
c b
v
d
e
f
q
p
j g
o
h
n Ii
k
w t
62056

Power Trim
h- Up circuit pressure‑operated check valve t- Low‑pressure oil
i- Shuttle spool u- High‑pressure oil
When the trim switch is activated in the down position, the electric motor reverses direction. With the oil pump gears rotating
opposite of trim up, the flow of oil is reversed. Oil is drawn through the down circuit suction port, and into the oil pump gears.
The pump forces pressurized oil into the down passages. Oil slides the shuttle spool into the up circuit pressure‑operated valve.
The shuttle spool mechanically opens the up circuit pressure‑operated valve and allows oil from the up fluid cavity of the trim
cylinder to return into the oil pump. This oil, returning from the up fluid cavity, supplies the oil required for the down circuit. The
oil is blocked from returning into the reservoir by the ball inside the up circuit suction port. Oil, under pressure, opens the down
circuit pressure‑operated valve and enters the down passages inside of the manifold.
The manifold passage connects into the trim cylinder passage leading to the top of the cylinder. The cavity inside the cylinder
above the shock piston is the down fluid cavity. As the down fluid cavity fills with oil, the trim rod retracts into the cylinder,
lowering the outboard motor. Oil from the up fluid cavity exits the cylinder and is drawn back into the pump through the open up
circuit pressure‑operated valve. When the trim rod reaches full travel, the oil pressure inside the down circuit rises until the
down circuit pressure relief valve opens, bypassing oil back into the reservoir. When the trim button is released, the pump stops
supplying oil, both of the pressure‑operated valves close and, if open, the down circuit pressure relief valve closes. The closed
valves lock the fluid on either side of the shock piston and memory piston, holding the outboard motor in position.

Power Trim
Maximum Tilt
v
q
p
o u
n c b
e d
f
w t
j g
h
Ii
k
62051

Power Trim
h- Up circuit pressure‑operated check valve t- High‑pressure oil
i- Shuttle spool u- Low‑pressure oil
With the trim rod fully extended at the maximum tilt position, the pressure inside of the trim cylinder increases to the pressure
setting of the up circuit pressure relief valve. Pressure forces the relief valve to open, allowing high‑pressure oil to return to the
reservoir through passages in the manifold. Oil flow continues until the up button is released.

Power Trim
Maximum Trim Down
s
r
v
c b
d
e
j g
h
p q Ii
k
o
n
w t
l
62054

Power Trim
With the trim rod fully collapsed in the maximum trim down position, the pressure inside of the trim cylinder increases to the
pressure setting of the down circuit pressure relief valve. Pressure forces the relief valve to open, allowing high‑pressure oil to
return to the reservoir through passages in the manifold. Oil flow continues until the down button is released.

Power Trim
Shock Function Up
s
r
v u
p q
c b
o
n d
e
j g
w t
h
Ii
k
62053

Power Trim
j- Down‑circuit pressure‑operated check valve v- Down fluid cavity
Oil inside the down fluid cavity is locked in a static position by the closed down circuit pressure‑operated valve, and the manual
release valve. If the outboard strikes an underwater object while in forward gear, the trim rod tries to rapidly extend from the
cylinder, increasing the pressure inside the trim cylinder down fluid cavity and connecting passages. When the pressure
increases to the relief valve setting, the impact relief valves located inside the shock piston open and allow the fluid to pass
through the shock piston. As the fluid passes through the piston, the trim rod extends from the trim cylinder. The memory piston
remains held in position by vacuum created by the oil in the up fluid cavity being locked in a static position.

Power Trim
Shock Function Return
s
r
p q
c b
o
n
d
e
j g
h
iI
t k
62052

Power Trim
a- Electric motor l- Manual release valve
b- Reservoir oil m- Cylinder
c- Oil pump n- Memory piston
d- Down circuit suction ball o- Shock piston
e- Up circuit suction ball p- Impact relief valve
f- Down circuit pressure relief valve q- Shock return valve
g- Up circuit pressure relief valve r- End cap
h- Up circuit pressure‑operated check valve s- Trim rod
i- Shuttle spool t- Up fluid cavity
j- Down circuit pressure‑operated check valve u- Down fluid cavity
k- Thermal relief valve v- Oil between shock and memory pistons
After the engine clears the underwater object, the weight of the engine increases the oil pressure between the memory piston
and shock piston to the level required to open the shock return valve inside the shock piston. This allows the oil to bleed back
through the shock piston into the down fluid cavity. This returns the engine back against the memory piston and into the original
running position.

Power Trim
Manual Tilt
s
r
c b
p q
d
o e
n f
j g
h
Ii
k
62050

Power Trim
a- Electric motor l- Manual release valve
b- Reservoir oil m- Cylinder
c- Oil pump n- Memory piston
d- Down circuit suction ball o- Shock piston
e- Up circuit suction ball p- Impact relief valve
f- Down circuit pressure relief valve q- Shock return valve
g- Up circuit pressure relief valve r- End cap
h- Up circuit pressure‑operated check valve s- Trim rod
i- Shuttle spool t- Up fluid cavity
j- Down circuit pressure‑operated check valve u- Down fluid cavity
k- Thermal relief valve
To manually tilt the outboard engine, back out the manual release valve 3–4 turns. With the valve backed out, the internal
passages inside the manifold are connected. These passages connect both the cylinder down and up fluid cavities, along with
the reservoir, allowing the engine to be raised or lowered. Trim rod movement continues until the manual release valve is
closed, locking the fluid inside of the cylinder and manifold.
When trimming the outboard in either the up or down position, with the manual tilt valve open or leaking, little or no movement
occurs. Oil pressure from the pump moves to both the up fluid cavity, and through the manual tilt valve into the down fluid
cavity. There is equal pressure in each cavity, resulting in little or no movement.
IMPORTANT: Do not operate the outboard or trim the outboard in either the up or down direction with the manual tilt valve
open. Damage to the O‑rings may occur. Close the manual release valve before operating the trim or the outboard.
Reverse Operation
To prevent the outboard from coming up or trailing out, when shifted into reverse and/or throttling back rapidly, oil in the trim
system must be locked in a static position. This is accomplished with the up and down circuit pressure‑operated check valves.
When the pump is not operating, the shuttle valve is in a centered position and the pressure‑operated check valves are held
closed by the springs behind the valve poppet. Oil is now locked in both ends of the cylinder preventing the trim rod from
moving in or out.
General Hydraulic Service Recommendations

! CAUTION
Contamination can damage the hydraulic system or cause the system to malfunction. Failure of power trim or steering
components can result in injury or product damage. Ensure that the work area, shop tools and all components are clean and
lint free during reassembly.
There may be more than one way to disassemble or reassemble a particular part, therefore, it is recommended that the entire
procedure be read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
In many cases, complete disassembly may not be necessary, until cleaning and inspection reveals that disassembly is required
for replacement of one or more components.
Service procedure order in this section is a normal disassembly/reassembly sequence. It is suggested that the sequence be
followed without deviation to ensure proper repairs. When performing partial repairs, follow the instructions to the point where
the desired component can be replaced, then proceed to reassembly and installation of that component in the reassembly part
of this section. Use the Table of Contents to find the correct page number.
When removing components, place the contents in a clean plastic bag. Seal the bag and label the contents for later assembly
and installation.
Cap or plug all open hydraulic connections.
Do not use cloth rags to clean components, lint may contaminate the system.
Threaded parts are right‑hand (RH), unless otherwise indicated.
When holding, pressing, or driving is required, use soft metal vise jaw protectors or wood for protection of parts. Use a suitable
mandrel (one that will contact only the bearing race) when pressing or driving bearings.
Whenever compressed air is used to dry a part, verify that no water is present in the air line.
Seals
As a normal procedure, all O‑rings and oil seals should be replaced without regard to appearance. When using Loctite on seals
or threads, surfaces must be clean and dry. To ease installation, apply Power Trim and Steering Fluid or automatic
transmission fluid (ATF) (Type Dexron III) on all O‑rings. To prevent wear, apply 2‑4‑C with PTFE on l.D. of oil seals.

Power Trim

28 Dexron III Automatic O-rings Obtain Locally
95 2-4-C with PTFE Inside diameter of oil seals 92-802859A 1

114 O-rings 92-858074K01
Fluid
Power Trim System Pressure Tests

Up Pressure Check
IMPORTANT: This test will not locate problems in the trim system. The test will measure system pressure. If minimum
pressures are not obtainable, the trim system requires additional repair.
IMPORTANT: Ensure the battery is fully charged (12‑volt minimum) before performing the following tests.
1. Tilt the outboard to the full up position and engage the tilt lock lever.
2. Slowly remove the fill plug to bleed pressure from the reservoir.
3. Remove the circlip securing the manual release valve and unscrew the release valve from the trim assembly.
NOTE: A small amount of trim fluid may drip from the manual release valve hole. Place a suitable container under the trim
assembly to collect any leakage.
4. Install the pressure adapter fitting into the manual release valve hole.
5. Thread the hose from the pressure gauge kit into the brass fitting on the adapter fitting.
6. Open valve "c" and close valve "d."
b e
b
c d
48718
a- Pressure adapter fitting

b- Pressure gauge hose ‑ adapter fitting to pressure gauge
c- Valve "c"
d- Valve "d"
e- Pressure gauge
Pressure Adapter Fitting ‑ Up 8M0061797

7. Install the fill plug.
8. Run the trim up and disengage the tilt lock lever.
9. Run the trim up to the full up position. Record the pressure reading on the gauge. Release the trim switch.
Power Trim
Up pressure (minimum) 18,616 kPa (2700 psi)

Power Trim
10. Run the trim down to release pressure.
11. Tilt the outboard full up and engage the tilt lock lever.
12. Slowly remove the fill plug to bleed trapped pressure.
13. Remove the pressure gauge hose and pressure adapter fitting.
14. Install the manual release valve and secure the valve with a circlip.
15. Tighten the fill plug.
NOTE: If the pressure is out of the specified pressure range, troubleshoot the system. Refer to Trim System Hydraulic
Troubleshooting.
Down Pressure Check

IMPORTANT: This test will not locate problems in the trim system. The test will measure system pressure. If minimum
pressures are not obtainable, the trim system requires additional repair.
IMPORTANT: Ensure the battery is fully charged (12‑volt minimum) before performing the following tests.
1. Tilt the outboard to the full up position and engage the tilt lock lever.
2. Slowly remove the fill plug to bleed pressure from the reservoir.
3. Remove the circlip securing manual release valve and unscrew the release valve from the trim assembly.
NOTE: A small amount of trim fluid may drip from the manual release valve hole. Place a suitable container under trim
assembly to collect any leakage.
4. Install the pressure adapter fitting into the manual release valve hole.
5. Thread the hose from the pressure gauge kit into the brass fitting on the adapter fitting.
6. Open valve "c" and close valve "d."
b e
b
c d
48718
a- Pressure adapter fitting

b- Pressure gauge hose ‑ adapter fitting to pressure gauge
c- Valve "c"
d- Valve "d"
e- Pressure gauge
Pressure Adapter Fitting ‑ Down 8M0054662

7. Install the fill plug.
8. Tilt the outboard full up and disengage the tilt lock lever.
9. Run the trim to the full down position. Record the pressure reading on the gauge. Release the trim switch.
Power Trim
Down pressure 3730–6150 kPa (540–890 psi)

Power Trim
10. Tilt the outboard full up and engage the tilt lock lever.
11. Slowly remove the fill plug to bleed trapped pressure.
12. Remove the pressure gauge hose and pressure adapter fitting.
13. Install the manual release valve and secure the valve with a circlip.
14. Tighten the fill plug.
NOTE: If the pressure is out of the specified pressure range, troubleshoot the system. Refer to Trim System Hydraulic
Troubleshooting.
Trim System Hydraulic Troubleshooting

Troubleshooting
Support the outboard with a tilt lock pin when servicing the power trim system.
IMPORTANT: After debris or failed components have been found, it is recommended that unit be disassembled completely and
all O‑rings be replaced. Check valve components and castings must be cleaned using engine cleaner and compressed air, or
replaced prior to reassembly.
IMPORTANT: Power trim system is pressurized. Outboard must be in the full up position (trim rod fully extended) prior to fill/
drain plug or manual release valve removal.
1. Refer to instructions following if disassembly is required when servicing.
2. Follow preliminary checks before proceeding to troubleshooting flow diagrams following.
Preliminary Checks
IMPORTANT: Operate power trim system after each check to see if problem has been corrected. If the problem has not been
corrected, proceed to next check.
1. Ensure manual release valve is tightened to full clockwise position.
2. Check trim pump fluid level with outboard in full up position and fill if necessary. Refer to Purging Power Trim System in
this section.
3. Check for external leaks in power trim system. Replace defective parts if leak is found.
4. Outboard not holding tilted position (falls down to trim position) indicates debris or defective components in trim assembly.
Clean or replace components as required.
Power Tilt Leakage Test Procedure

Method 1
1. Extend the power tilt cylinder to the full up position.
2. Measure the distance between the cylinder cap and the bottom of the power tilt cylinder rod eye.
3. Wait 24 hours and measure the distance again.
a- Cylinder rod
b- Rod eye
c- Cylinder cap
d- Measured distance
b
d
a
c
36840
Power Tilt System Leakage Specification

Cylinder rod leak‑down in 24 hour period Less than 55 mm (2.2 in.)
Method 2
1. Extend the power tilt cylinder to the full up position.

Power Trim
2. Mark the tilt cylinder rod 55 mm (2.2 in.) above the cylinder cap with an indelible marker.
3. Wait 24 hours.
4. If the marked line is visible, the power tilt unit is within specifications for leakage.
Power Tilt System Leakage Specification

Cylinder rod leak‑down in 24 hour period Less than 55 mm (2.2 in.)
Hydraulic System Troubleshooting

Condition/Problem
Condition of Trim System Problem No.
Trim motor runs; trim system does not move up or down 1, 2, 5, 7, 10
Does not trim full down, up trim OK 3, 4, 7, 13, 14
Does not trim full up, down trim OK 1, 4, 6, 7, 11, 12
Partial or jerky down/up 1, 11
Does not trim up (under load) 2, 5, 6, 8, 12
Does not hold trim position (under load) 4, 5, 6, 7, 15
Trails out when backing off from high speed 3, 4
Leaks down and does not hold trim (no load) 4, 5, 6, 7, 15
Trim motor working hard and trims slow up and down 2, 8, 9
Trims up very slow 1, 2, 5, 6, 8, 9
Starts to trim up from full down position when the down trim button is depressed 3, 4
Trim position will not hold in reverse (under load) 3, 4, 5, 14, 15
Problem/Solution
No. Problem Solution
1. Low fluid level Add Power Trim and Steering Fluid or ATF (Type Dexron III).
Pressure test the pump. Refer to Power Trim System Pressure
2. Defective hydraulic pump
Tests.
Inspect ball seat for nicks or contamination. Replace shock rod
3. Trim cylinder shock piston ball not seated
assembly.
Trim cylinder piston or memory piston O‑rings
4. Inspect O‑rings for cuts or abrasion.
leaking or cut
5. Manual release valve leaking Ensure that valve is fully closed. Inspect O‑rings.
6. Up thermal relief valve not seated Inspect seat for debris and damage.
7. Debris in system Inspect for debris. Refill system with clean fluid.
8. Battery low Check battery.
9. Electric motor defective Refer to Electrical System Troubleshooting.
10. Broken motor/pump coupler Inspect for damage.
11. Air in the hydraulic system Purge system. Refer to Purging Power Trim System.
12. Defective up relief valve Inspect for debris and damaged components.
13. Defective down relief valve Inspect for debris and damaged components.
Inspect seat for debris and damage. If damaged, replace the manual
14. Down thermal relief valve not seated
release valve.
15. Pressure‑operated check valve leaking Inspect for debris and a damaged check seat.

Power Trim
Electrical System Troubleshooting

BLK Black BLU Blue
BRN Brown GRA Gray
PNK Pink PPL Purple
RED Red TAN Tan
LT Light DK Dark
Before Troubleshooting
General Checks
Before troubleshooting the power trim electrical system, check the following:
• Disconnected wires
• Connections are tight and corrosion free
• Plug‑in connections are fully engaged
• Battery is fully charged
Condition/Problem
Condition of Trim System Problem No.
The trim motor does not run when the trim button is depressed 1, 2, 4, 5, 6, 7
The trim system trims opposite of the buttons 3
The cowl‑mounted trim buttons do not activate the trim system 2, 4, 5, 6
Problem/Solution
No. Problem Solution
1. Battery is low or discharged Check the battery.
2. Open circuit in the trim wiring Check for an open connection.
Wiring is reversed in the remote control, cowl switch, or
3. Verify all the connections.
trim leads
4. Wire harness is corroded through Replace the wiring harness.
5. Internal motor problem (brushes, shorted armature) Check for an open connection. Replace the motor.
6. Trim switch failure Replace the switch.
Verify that all relays are functioning correctly. Check the
7. Relay not operating
voltage at the trim bullets.
Trim Circuit
When the relays are de‑energized, contacts 30 and 87a complete the circuit to the trim motor leads. Both motor leads are to
ground.

Power Trim
When contact 85 is energized from the trim switch, the up relay is energized. Contacts 30 and 87 close, completing the circuit
to 12 V (+) to the blue trim motor lead. The trim down relay remains de‑energized. The trim motor tilts the engine up.
d (+) BLK
a- Trim relay contacts
LT BLU/WHT
b- Trim up relay
a RED (+) e c- Trim down relay
87
85 87a 87 d- To trim up switch
87a b e- 12 V (+)
86 85 f- To trim motor (+)
86 30
30 g- To trim motor (–)
h BLK/WHT
h- To ECU connector pin‑2
BLU
(+) f
GRN/WHT
RED (+)
85 87a 87
c
86 30
GRN
(–) g 71435
Power Trim Relay Test Procedure

The trim motor relay system, used on permanent magnet motors, connects each of the two wires from the trim motor to either
ground or positive to allow the motor to run in both directions.
If the motor will not run in the up direction, it may be either the up relay is not making contact to 12 volts or the down relay is not
making contact to ground. The opposite is true if the system will not run down. When the system is not energized, both relays
should connect the heavy motor leads to ground.
To test which relay is faulty if the trim system does not operate in one direction:
NOTE: The up and down relays do not have to be removed from the electrical cover to perform these tests.
1. Disconnect the heavy gauge blue and green pump wires from the up and down relay wire connectors.
2. Check for continuity between the heavy leads from the trim relays to ground.
Meter Test Leads

Red Black
Green Ground Full continuity (Ω) < 20
Blue Ground Full continuity (Ω) < 20
3. Replace the relay that does not have continuity.
NOTE: To remove the power trim relays, refer to Power Trim Relay Removal.
4. Connect a voltmeter to the heavy blue lead and to ground. There should be 12 volts on the blue lead when the up switch is
pushed and 12 volts on the green lead when the down switch is pushed. Replace the relay that does not switch the lead to
positive.
Meter Test Leads

Meter Scale Test Condition Reading (VDC)
Red Black
Blue Ground DC volts Up switch pushed 12 volts
Green Ground DC volts Down switch pushed 12 volts

Power Trim
Power Trim Relay Removal and Installation

Removal
1. Remove the three screws and washers securing the electrical cover to the cylinder block.
48216
2. Rotate the electrical cover to access the components on the cover.

3. Cut five cable ties securing the engine harness to the electrical cover. Pull the engine harness out of the electrical cover
openings.
48218
4. Unlatch all of the relays and remove the up and down relays from the electrical cover.
NOTE: To remove the power trim relays, insert a flat blade screwdriver in the relay lock tab. Gently twist the blade and pry
the relay loose. Pull the relay out. Do not pull with the wires.

Power Trim
5. Remove the up and down relays from the engine harness connector.
a- Main power relay

b- Start relay
c- Up relay
d d- Down relay
c
a
48219
Installation
1. Install the up and down relays 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 up and down relays 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.

Power Trim
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 –

Power Trim
Power Trim Electrical Circuit Diagram
e
b c d
2 f
S110
6 g
GRY
h
a
5 1
4 8
7
i
49215
k j
a- Engine control module (ECM)

b- Main power relay
c- Trim down relay
d- Trim up relay
e- Trim switch
f- Down motor lead
g- Up motor lead
h- 14‑pin engine harness connection
i- Fuse holder
j- Cowl trim switch
k- Trim position sensor
Troubleshooting the Power Trim Electrical System

Troubleshooting the Down Circuit
NOTE: Refer to the preceding wiring diagrams for connection points when troubleshooting the electrical systems. Connection
points are specified by number.

Power Trim
Step Test Procedure Test Result

Battery voltage measured:
• Go to step 2.
Step 1: Check for No battery voltage measured:
Connect the voltmeter red lead to point 3
battery voltage at point • There is an open circuit between point 3 and the
and the black lead to ground.
3. positive (+) battery terminal.
• Check for loose or corroded connections.
• Check the wires for an open circuit.
Disconnect the 14‑pin engine harness
connector and both the heavy green and Battery voltage measured:
blue power trim bullet connectors in the • Reconnect the 14‑pin harness connector.
Step 2: Check for
front lower cowling. Connect the
battery voltage at point • Go to step 4.
voltmeter red lead to point 1 (pin J of the
1. No battery voltage measured:
engine harness connector) and black
lead to ground. Press and hold the cowl • Go to step 3.
down tilt switch.
• The trim switch is faulty.
Connect the voltmeter red lead to point 5
battery voltage at point • Check for a loose or corroded wire at point 5.
and the black lead to ground.
5. • There is an open circuit in the wire supplying current
to point 5, including the 15‑amp fuse in E and F of N
fuse holder.
Step 4: Check for Connect the voltmeter red lead to point 2
• Go to step 5.
battery voltage at point and the black lead to ground. Press and
No battery voltage measured:
2. hold the trim down switch.
• The down relay is defective. Replace the down relay.
Step 5: Check relay Battery voltage measured:
ground connection Connect the voltmeter red lead to point 3 • Go to step 6.
between points 3 and and the black lead point 6. No battery voltage measured:
6. • The up relay is defective. Replace the up relay.
Relay is good:
• The pump motor wiring is defective.
Step 6: Check the up Test the up relay. Refer to Power Trim
relay. Relay Test Procedure preceding. • The pump motor is defective.
Relay is faulty:
• Replace the relay.
Troubleshooting the Up Circuit

NOTE: Refer to the preceding wiring diagrams for connection points when troubleshooting the electrical systems. Connection
points are specified by number.

• Go to step 2.
Connect the voltmeter red lead to point
battery voltage at point • There is an open circuit between point 3 and the
3 and the black lead to ground.
3. positive (+) battery terminal.
• Check for loose or corroded connections.
• Check the wires for an open circuit.

Power Trim

Disconnect the 14‑pin engine harness
connector and both the heavy green
and blue power trim bullet connectors in • Reconnect the 14‑pin harness connector and both
Step 2: Check for heavy green and blue power trim bullet connectors.
the front lower cowling. Connect the
battery voltage at point
voltmeter red lead to point 8 (pin H of • Go to step 4.
8.
the engine harness connector) and No battery voltage measured:
black lead to ground. Press and hold
• Go to step 3.
the cowl trim up switch.
• The trim switch is faulty.
Connect the voltmeter red lead to point
battery voltage at point • Check for a loose or corroded wire at point 5.
5 and the black lead to ground.
5. • There is an open circuit in the wire supplying current
to point 5, including the 15‑amp fuse in E and F of N
fuse holder.
Step 4: Check for Connect the voltmeter red lead to point
• Go to step 5.
battery voltage at point 6 and the black lead to ground. Press
No battery voltage measured:
6. and hold the trim up switch.
• The up relay is defective. Replace the up relay.
Step 5: Check relay
Connect the voltmeter red lead to point • Go to step 6.
ground connection
3 and the black lead point 2. No battery voltage measured:
between points 3 and 2.
• The down relay is defective. Replace the down relay.
Relay is good:
Step 6: Check the down • The pump motor wiring is defective.
Test the down relay. Refer to Power
relay, if you have not • The pump motor is defective.
Trim Relay Test Procedure preceding.
done this previously. Relay is faulty:
• Replace the relay.
Troubleshooting the Up and Down Circuits (All Circuits Inoperative)

NOTE: Refer to previous wiring diagram for location of wire connections.
Problem Possible Cause Remedy

1. Faulty trim switch. 1. Replace the trim switch.
The up and down trim switches are both
inoperative, but the cowl switch does 2. A wire is open between the fuse
operate. holder and the trim switch, 2. Check for a loose or corroded connection.
including the 15‑amp fuse.
1. Replace the fuse. Locate the cause of the
1. The 15‑amp fuse blown. blown fuse. Check electrical wiring for a shorted
circuit.
2. One of the trim pump motor
2. Check the wire connections at point 2 or 6 for
wires is open between the motor
loose or corroded condition.
and the relays.
Trim switch and cowl switch are both 3. If voltage is present at the connections at point
inoperative. 2 or 6 when the appropriate trim button is
3. Faulty trim pump motor.
pressed, then the motor is faulty. Replace the
motor.
4. Check the trim relays. Refer to Power Trim
4. Faulty trim relay.
Relay Test Procedure.
5. A wire is open between the fuse
5. Check for an open connection or a cut wire.
holder and the solenoid.
Trim system operates (motor runs)
The trim or cowl switch is shorted. Replace the trim switch.
without pressing the switches.

Power Trim
Power Trim System Removal

! WARNING
Damaged wires can cause electrical problems, resulting in system failure. In some cases, this can affect boat operation,
leading to personal injury. Use conduit, hose clamps, grommets, or other appropriate measures to protect all electrical wires.
Do not overtighten clamps and keep harnesses away from heat sources during installation.
1. Tilt the outboard to the full up position and support with the tilt lock lever.
2. Remove the screws securing the trim position sensor.
a- Trim position sensor

b- Screw (2)
a c- Tilt lock knob
d- Tilt lock lever
b
d
c
48560
3. Remove the upper pivot pin screw.
4. Drive out the upper pivot pin.
5. Retract the trim cylinder rod approximately 5 cm (2 in.).
a - Upper pivot pin screw

b - Upper pivot pin
48561

Power Trim
6. Disconnect the trim wire harness connectors.
a - Trim wire harness connectors

b - Trim position sensor connector
48563
7. Pull the trim harness through the grommet in the cowl and the trim harness retainer.
a- Trim harness retainer

a
b- Trim harness
c- Grommet
b d- Screw
e- Ground cable
c
d
e
48562
8. Remove the screw and J‑clip securing the power trim harness to the transom bracket.
a- Screw
b- J‑clip
c- Cable tie
a
d- Harness
b
c
d
48775

Power Trim
9. Remove the two bolts securing the ground cables and anode to the power trim unit.
a- Power trim unit

d b- Anode
c- Bolt (M6 x 25)
a d- Ground cable
c
b
48569
10. Remove the bolt and flat washer from each transom bracket securing the lower pivot pin.
a - Bolt (M8 x 35)

b - Washer
b
48570
11. Use suitable punch to drive out lower pivot pin while supporting the power trim unit.
a - Lower pivot pin

b - Eccentric retaining bolt hole
a
49186

Power Trim
12. Pivot the power trim assembly forward then up and out from the clamp brackets and remove assembly.
48571
Power Trim Disassembly—Design 1

Draining the Power Trim Fluid
IMPORTANT: Power trim system is pressurized. The trim cylinder rod must be fully extended in the up position prior to
removing the reservoir plug or manual release valve.
1. Extend the trim cylinder rod to the full up position.
2. Remove reservoir plug.
3. Remove manual release valve assembly.
4. Drain the fluid into a clean container.
5. Inspect the fluid for contamination.
a - Reservoir plug
b - Manual release valve
48685

Power Trim
Lower Pivot Bushings

Remove the lower pivot bushings.
48756
Filter
IMPORTANT: The power trim system is pressurized. The trim cylinder rod must be fully extended in the up position prior to
2. Remove the filter plug from the power trim unit.
3. Remove the filter element.
4. Clean the filter element.
5. Ensure that the O‑ring is in place on the element.
6. Install the filter element into the power trim unit.
7. Install the plug.
a - Plug
b - Filter element
c - Filter element O‑ring
c b a
48686
8. Add Power Trim and Steering Fluid to the reservoir. Refer to Section 1B ‑ Checking Power Trim Fluid.

Fluid
9. Purge any air from the power trim system. Refer to Purging Power Trim System.

Power Trim
Power Trim Pump and Motor

NOTE: The pump is not serviceable and is replaced as a complete assembly.
1. Remove the power trim unit from the outboard. Refer to Power Trim System Removal.
2. Drain the fluid from the reservoir into a clean container. Refer to Draining the Power Trim Fluid.
3. Secure the power trim unit in a soft jawed vice.
4. Remove the two bolts securing the electric motor and remove the motor.
a - Motor
b - Bolt
a
b
b
48594
5. Remove the coupler.

6. Remove the two bolts securing the pump to the base.
a a - Pump
b b - Bolt
c - Coupler
48595

Power Trim
7. Clean the reservoir and the oil passages in the reservoir.
48597
Trim Motor Electrical Tests

Connect a 12‑volt supply to the motor leads. If the motor fails to run, replace the motor assembly.
NOTE: The trim motor is not serviceable.
Manual Release Valve

IMPORTANT: The power trim system is pressurized. The trim rod must be fully extended in the up position, prior to removing
the fill/drain plug or manual release valve.
NOTE: The down thermal relief valve is contained in the manual release valve assembly and is nonserviceable.
Removal
1. Remove the circlip (if the power trim unit is installed on the outboard).
2. Remove the manual release valve assembly.
Installation
1. Inspect the O‑rings for abrasion or cuts. Replace as necessary.
2. Lubricate the O‑rings with clean fluid.
3. Install the manual release valve into the body.
4. Install the circlip (if removed).
5. Fill the reservoir with clean Power Trim and Steering Fluid.
a a - Circlip
b b - O‑rings
48781

114 Power trim system reservoir and O-ring lubrication 92-858074K01
Fluid

Power Trim
Pressure‑Operated (PO) Check Valve

1. Remove the two plugs from the power trim unit.
2. Remove the check valve components.
NOTE: Use the expanding collet to remove the two seats.
NOTE: The shuttle spool may be removed from either side.
Use a drift punch to push the shuttle spool out.
a- Shuttle spool
b- Seat (2)
c- Poppet (2)
d- Spring (2)
e- Plug (2)
b c d e
e d c b a
48656

3. Place the components in a clean plastic bag and label the contents.
Pressure Relief Valves

IMPORTANT: The up and down pressure relief valve components are identical except for the spring. The up relief valve uses
the stiffer spring because of the higher circuit pressure.
1. Remove the up pressure relief valve plug from the power trim unit.
2. Remove the relief valve components.
NOTE: Store the up relief valve components in a clean plastic bag and label the bag for identification.
a- Plug
b- Ball
c- Spring guide
d- Spring
e- Up pressure relief valve
f- Down pressure relief valve
e
d c b a
f
48682
3. Remove the down pressure relief valve plug from the power trim unit.

Power Trim
NOTE: Store the down relief valve components in a clean plastic bag and label the bag for identification.
Thermal Relief Valve

1. Remove the thermal relief valve plug from the power trim unit.
2. Remove the thermal relief valve components.
a- Plug
b- Spring
c- Plunger
d- Ball
e- Seat
f- Up pressure thermal relief valve
f e d c b a
48683

3. Place the components in a clean plastic bag and label the contents.
Trim Cylinder and Shock Piston

3. Drain the fluid. Refer to Draining the Power Trim Fluid.
4. Remove the trim cylinder end cap.
a - Trim cylinder end cap

b - Trim cylinder rod
a b
48690

5. Drain any remaining fluid from the cylinder.

Power Trim
6. Remove the trim cylinder rod.
7. Inspect the shock piston for debris in any of the seven impact relief valves and the shock return valve.
IMPORTANT: If debris is found in any of the valves, the piston is likely leaking and does not hold trim position. The shock
piston is not serviceable. Replace the shock piston/rod/end cap assembly.
b a - Impact relief valve (7)

b - Shock return valve
48791
Memory Piston Removal

1. Use lockring pliers or a suitable tool to remove the memory piston from the cylinder.
a - Lockring pliers
7127

2. Remove the O‑ring from the memory piston.
a - Memory piston
b - O‑ring
a
b
48711

Power Trim
Power Trim Disassembly—Design 2

Draining the Power Trim Fluid
2. Remove reservoir plug.
3. Remove the internal circlip from the manual release valve boss.
a - Reservoir plug
b - Manual release valve
70582

Remove the lower pivot bushings.
70584
Filter
IMPORTANT: The power trim system is pressurized. The trim cylinder rod must be fully extended in the up position prior to

Power Trim
2. Remove the motor from the power trim unit.
a - Motor
b - Bolt
b
b
70587
a a - Pump
b - Bolt
c - Coupler
b b
c
70589
5. Remove the filter keeper spring.
a - Filter keeper spring
70591
6. Carefully remove the filter and clean the filter to remove any debris.
70594

Power Trim
Power Trim Pump and Motor

NOTE: The pump is not serviceable and is replaced as a complete assembly.
2. Drain the fluid from the reservoir into a clean container. Refer to Draining the Power Trim Fluid.
3. Secure the power trim unit in a soft jawed vice.
4. Remove the two bolts securing the electric motor and remove the motor.
a - Motor
b - Bolt
b
b
70587
a a - Pump
b - Bolt
c - Coupler
b b
c
70589
7. Clean the reservoir and the oil passages in the reservoir. Do not lose the keeper spring in the filter cavity.
a - Filter keeper spring
70591
Trim Motor Electrical Tests

Connect a 12‑volt supply to the motor leads. If the motor fails to run, replace the motor assembly.
NOTE: The trim motor is not serviceable.

Power Trim
Reservoir Protection Valve
a - Reservoir protection valve location
70643
1. Remove the valve components from the valve bore.

2. Inspect the O‑rings on the valve assembly and the valve plug bolt.
a - Reservoir protection valve assembly

b - Plug bolt
a b 71019
3. Clean off any debris from the valve components and replace any damaged O‑rings.

IMPORTANT: The power trim system is pressurized. The trim rod must be fully extended in the up position, prior to removing
the reservoir plug or manual release valve.
a - Manual release valve location
a
70711
NOTE: The thermal relief valve is contained in the manual release valve assembly and is nonserviceable.
Removal
1. Remove the circlip.
Installation

Power Trim

4. Install the circlip.
a b a - Circlip
b - O‑rings
70596

Fluid

1. Remove the valve plug using the 4‑pin spanner socket tool.
4‑pin spanner plug socket 8M0174135
For removing and installing the PO valve plug

71570
2. Using an angled or 90° pick tool, remove the spring guide from the centering plate.
3. Remove the valve spring and diaphragm cup.
4. Using an angled or 90° pick tool, remove the centering plate by inserting the pick tool into the hole in the inside wall of the
centering plate.
5. Using an angled or 90° pick tool, remove the sleeve by inserting the pick tool into one of the two holes in the side wall of
the sleeve.
6. Remove the spool from the sleeve.
a b c d e f a- Spring guide
b- Valve spring
c- Diaphragm cup
d- Centering plate
e- Spool
f- Sleeve
g- Pick tool removal
points
g g g 70613
7. Clean all of the pieces and inspect the O‑rings and seals for cracks or damage.
NOTE: The backup ring on the spool has an angled split that is required in order to install the ring onto the spool. This is
normal and should not be considered damage.
Pressure Relief Valves

IMPORTANT: The up and down pressure relief valve components are identical except for the length of the spring and the
spring guide. The up relief valve uses the stiffer spring because of the higher circuit pressure.
1. Remove the up pressure relief valve plug from the power trim unit.
NOTE: An angled or 90° pick will aid in the removal of the valve seat.

Power Trim
NOTE: Store the up relief valve components in a clean plastic bag and label the bag for identification.
a - Up pressure relief valve

b - Down pressure relief valve
a b
70639
a b c d e 70640
a- Valve seat
b- Ball
c- Spring guide
d- Spring
e- Plug bolt
3. Remove the down pressure relief valve plug from the power trim unit.
NOTE: Store the down relief valve components in a clean plastic bag and label the bag for identification.
Trim Cylinder and Shock Piston

3. Drain the fluid. Refer to Draining the Power Trim Fluid.

Power Trim
4. Unscrew the trim cylinder end cap with a trim cylinder end cap tool and slide it up the rod.
a - Trim cylinder rod

b - Trim cylinder end cap
70647

5. Drain any remaining fluid from the cylinder.
6. If not already removed, remove the manual release valve from the power trim unit. This will relieve the vacuum condition
inside the cylinder.
7. Remove the trim cylinder rod, shock piston and memory piston from the cylinder.
a b c a - Memory piston
b - Rod and shock piston assembly
c - End cap
70648
8. Inspect the O‑rings for wear or damage

9. Inspect the walls of the cylinder for damage.
10. Inspect the inside bottom of the cylinder for damage or debris. Remove any debris with an absorbent paper towel or clean
soft cloth.
70650
11. Inspect the shock piston for debris in any of the seven impact relief valves and the shock return valve.

Power Trim
IMPORTANT: If debris is found in any of the valves, the piston is likely leaking and does not hold trim position. The shock
piston is not serviceable. Replace the shock piston/rod/end cap assembly.
b a - Impact relief valve (7)

b - Shock return valve
48791
Memory Piston Removal

If the memory piston does not come out of the cylinder with the shock piston and rod assembly, use the following procedure to
remove the memory piston.
1. Use lockring pliers or a suitable tool to remove the memory piston from the cylinder.
a - Lockring pliers
7127

2. Inspect the O‑ring from the memory piston for wear or damage.
a - Memory piston
b - O‑ring
a
b
48711
Power Trim Cleaning, Inspection, and Repair

IMPORTANT: Components must be dirt and lint free. The slightest amount of debris in the power trim system could cause the
system to malfunction.

Power Trim
2. Inspect and clean the filter. Refer to Filter.
3. Clean all components with parts cleaner and dry with compressed air.
NOTE: It is recommended that all O‑rings in the trim system be replaced. Use O‑ring kit 8M0057770.
4. Inspect the power trim body for contamination.
5. Inspect the individual valve components for contamination and damage.
6. Clean the internal passages with parts cleaner and dry with compressed air.
7. Install new O‑rings when installing the components.
8. Lubricate all O‑rings with Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid
(ATF).

114 Power trim O-rings 92-858074K01
Fluid
Nonserviceable Components
• The end cap, cylinder rod, and shock piston are not serviceable except for the O‑rings. They must be replaced as a
complete assembly.
• The hydraulic pump is not serviceable except for the O‑rings.
• The electric motor is not serviceable.
• The down thermal relief valve is located in the manual release valve. If it is not functioning, the manual release valve must
be replaced.

Power Trim
Notes:

Power Trim
Power Trim Assembly—Design 1

O‑Ring and Seal Placement
12
13
11
11
3
3
1
6 8
10
4 2
7 1
3
3
6 4
5
7
8 9
49040

Power Trim
O-Ring and Seal Placement

O‑Ring Description Material Quantity O‑Ring I.D. O‑Ring O.D. O‑Ring Width
Pump base and up
3.68 mm 7.24 mm 1.78 mm
1 thermal relief valve Buna 3
(0.145 in.) (0.285 in.) (0.070 in.)
seat
5.87 mm 9.12 mm 1.63 mm
2 Relief valve plug Buna 2
(0.231 in.) (0.359 in.) (0.064 in.)
Pump base, PO check
6.07 mm 9.63 mm 1.78 mm
3 spool, and up thermal Buna 4
(0.239 in.) (0.379 in.) (0.070 in.)
relief valve plug
Manual release and 7.65 mm 11.20 mm 1.78 mm
4 Buna 2
filter (0.301 in.) (0.441 in.) (0.070 in.)
9.25 mm 12.80 mm 1.78 mm
5 Manual release valve Aquathane 1
(0.364 in.) (0.504 in.) (0.070 in.)
9.25 mm 12.80 mm 1.78 mm
6 PO check valve seats Buna 2
(0.364 in.) (0.504 in.) (0.070 in.)
Manual release and 10.82 mm 14.38 mm 1.78 mm
7 Buna 2
reservoir plug (0.426 in.) (0.566 in.) (0.070 in.)
12.42 mm 15.98 mm 1.78 mm
8 PO check valve plug Buna 2
(0.489 in.) (0.629 in.) (0.070 in.)
14.00 mm 17.55 mm 1.78 mm
9 Manual release Buna 1
(0.551 in.) (0.691 in.) (0.070 in.)
13.94 mm 19.18 mm 2.62 mm
10 Filter plug Buna 1
(0.549 in.) (0.755 in.) (0.103 in.)
Piston and memory 53.57 mm 60.63 mm 3.53 mm
11 Aquathane 2
piston (2.109 in.) (2.387 in.) (0.139 in.)
56.82 mm 62.05 mm 2.62 mm
12 End cap Buna 1
(2.237 in.) (2.443 in.) (0.103 in.)
69.57 mm 73.13 mm 1.78 mm
13 Electric motor/reservoir Buna 1
(2.739 in.) (2.879 in.) (0.070 in.)

Power Trim
O-Ring Size
NOTE: Refer to O‑Ring and Seal Placement chart on previous page for description.
2
11
6 12
9
13
10
49039
a - Inside diameter
b - Outside diameter
c - Width

Power Trim

1. Install lubricated O‑rings onto the shuttle spool, seats, and the pressure‑operated check valve plugs.
c b a b c a - Shuttle spool
b - Seat
c - Plug
48747
2. Install the seat, poppet, spring, and plug into the aft side of the pressure‑operated check valve bore. Tighten the plug to the
specified torque.
a- Seat
b- Poppet
c- Spring
d- Plug
a
b d
c
48748

Pressure‑operated check valve plug 14 124 –
3. Install the shuttle spool, seat, poppet, spring, and plug into the forward side of the pressure‑operated check valve bore.
Tighten the plug to the specified torque.
a- Shuttle spool
b- Seat
c- Poppet
d- Spring
e- Plug
e d c b a
48751

Power Trim

Pressure‑operated check valve plug 14 124 –
Up and Down Pressure Relief Valves

IMPORTANT: The up and down pressure relief valve components are identical except for the spring.
If the up and down pressure relief valve components become mixed, the up pressure spring is the stiffer of the two springs.
Up Pressure Relief Valve

1. Install a lubricated O‑ring onto the pressure relief valve plug.
2. Install the up pressure spring, spring guide, ball, and plug into the up pressure relief valve bore.
IMPORTANT: The up pressure relief valve uses the stiffer spring because of the higher circuit pressure.
3. Tighten the plug to the specified torque.
a- Plug
b- Ball
c- Spring guide
d- Spring
e- Up pressure relief valve
f- Down pressure relief valve
e
d c b a
f
48682

Relief valve plug 4 35.4 –
Down Pressure Relief Valve

1. Install a lubricated O‑ring onto the pressure relief valve plug.
2. Install the down pressure spring, spring guide, ball, and plug into the down pressure relief valve bore.
IMPORTANT: The down pressure relief valve uses the softer spring because of the lower circuit pressure.

Relief valve plug 4 35.4 –
Up Thermal Relief Valve

1. Install a lubricated O‑ring onto the up thermal relief valve seat and plug.
2. Install the seat, ball, plunger, spring, and plug into the up thermal relief valve bore.

Power Trim
a- Plug
b- Spring
c- Plunger
d- Ball
e- Seat
f- Up pressure thermal relief valve
f e d c b a
48683

Thermal relief valve plug 4 35.4 –
Trim Pump and Motor

1. Install new lubricated O‑rings onto the pump.
a a - Large O‑rings
b - Small O‑rings
b
48596
2. Install the pump onto the base. Tighten the bolts to the specified torque.
3. Install the coupler onto the pump input shaft.
a a - Pump
b b - Bolt
c - Coupler
48595

Power Trim

Pump mounting bolts 8 70.8 –
4. Install a new O‑ring onto the motor.
a - O‑ring
48598
5. Align the coupler to the motor shaft and install the motor onto the base.
6. Tighten the bolts to the specified torque.
a - Motor
b - Bolt
a
b
b
48594

Motor mounting bolts 9 79.6 –
Trim Cylinder
1. Install a new lubricated O‑ring onto the memory piston.
a - Memory piston
b - O‑ring
a
b
48711

Power Trim
2. Install new lubricated O‑rings onto the end cap and shock piston.
a - End cap O‑ring

b b - Shock piston O‑ring
a
48745
3. Place the memory piston into the cylinder bore.

4. Push the memory piston all the way to the bottom.
5. Fill the cylinder 75 mm (3 in.) from the top of the cylinder using Power Trim and Steering Fluid. If not available, use
automotive automatic transmission fluid (ATF).

114 Power trim system 92-858074K01
Fluid
6. Install the shock rod into the cylinder until the power trim fluid flows through the oil blow off ball passage.
7. Fill the cylinder to just below the cylinder threads.
IMPORTANT: The end cap must not make contact with the shock rod piston when tightening. The shock rod piston must
be positioned in the cylinder deep enough to avoid contact.
8. Tighten the end cap securely using a spanner wrench (6.4 mm x 8 mm [1/4 in. x 5/16 in.] long pegs). If a torquing type
spanner tool is used to tighten the end cap, then tighten the end cap to the specified torque.


End cap 100 – 73.7

1. Lubricate the bushings with 2‑4‑C with PTFE.
2. Install the lower pivot bushings into the power trim unit.
48756

Power Trim


Power Trim
Notes:

Power Trim
Power Trim Assembly—Design 2

O‑Ring, Washer, and Seal Placement
5
2
1
15
6
16
9
14
13
12
11
17 19
13 18
8
7
9
10 14
70654

Power Trim
O-Ring, Washer, and Seal Placement

O‑ring
Ref. No. Quantity Part Number
1 1 8M6008097
2 2 8M6008035
3 1 8M6008034
4 1 8M6008045
5 2 8M6008073
6 1 8M6008058
7 1 8M6008067
8 1 8M6008068
9 2 8M6008086
10 1 8M6008112
11 1 8M6008113
12 1 8M6008108
13 2 8M6008053
14 2 8M6008049
15 1 8M6008075
16 1 8M6008079
Seal
17 1 8M6008111
18 1 8M6008070
Washer
19 1 8M6008069

Power Trim

1. Inspect the check valve bore for any debris or material, clean out as needed.
2. Install the O‑rings and backup ring onto the check valve components.
a b a
a - O‑rings on centering
plate and spool
sleeve
b - Backup ring on spool
70655
3. Lubricate the O‑rings and outer surfaces of the valve components with Power Trim and Steering fluid.

114 O-rings and outer surfaces of valve components 92-858074K01
Fluid
4. Install the components into the valve bore.
5. Install the valve plug using the 4‑pin spanner socket tool, and tighten to the specified torque.
4‑pin spanner socket 8M0174135
For removing and installing the PO valve plug

71570

Pressure‑operated check valve plug 41 – 30.2
Up and Down Pressure Relief Valves

IMPORTANT: The up and down pressure relief valve components are identical except for the spring length and size, and the
length of the spring guide.
If the up and down pressure relief valve components become mixed, the up pressure spring is the larger of the two springs. The
longer spring guide is for the up pressure relief valve.
a - Up pressure relief valve

b - Down pressure relief valve
a b
70639

Power Trim
Up Pressure Relief Valve

1. Install a lubricated O‑ring onto the pressure relief valve plug and the valve seat.
a b
70656
a - O‑ring on valve seat

b - O‑ring on valve plug
2. Install the valve seat, up pressure spring, spring guide, ball, and plug into the up pressure relief valve bore.

Relief valve plug 6.4 56.6 –
Down Pressure Relief Valve

1. Install a lubricated O‑ring onto the pressure relief valve plug and the valve seat.
a b
70656
a - O‑ring on valve seat

b - O‑ring on valve plug
2. Install the valve seat, up pressure spring, spring guide, ball, and plug into the up pressure relief valve bore.
NOTE: The ground flat end of the down relief valve spring must be inserted into the valve plug assembly.

Relief valve plug 6.4 56.6 –

Power Trim
Reservoir Protection Valve
a - Reservoir protection valve location
70643
1. Place the O‑rings on the valve assembly and the valve plug bolt.
a - Reservoir protection valve assembly

b - Plug bolt
a b 71019
2. Install the valve components into the valve bore. Tighten the plug bolt to the specified torque.

Reservoir protection valve plug 6.4 56.6 –

4. Install the circlip.
a b a - Circlip
b - O‑rings
70596

Fluid

Power Trim
Filter
1. Inspect the pump housing surfaces for any material or debris that may have fallen into the housing. Clean out as needed.
70658
2. Insert the filter first, followed by the spring.
a - Filter ‑ inserted first

b - Spring ‑ inserted second
b
70703
Trim Pump and Motor

1. Inspect the pump housing surfaces for any material or debris that may have fallen into the housing. Clean out as needed.
70658

Power Trim
2. Insert the two small O‑rings and the spring into the housing.
70659
3. Position the pump in the housing and start the two mounting screws by hand. After several turns by hand, tighten the
screws to the specified torque
70660

Pump mounting screws 10.2 90.2 –
4. Install the pump‑to‑motor coupler.
70661

Power Trim
5. Install the motor assembly onto the pump housing with two screws. Tighten the two screws to the specified torque.
70664

Motor mounting bolts 4.5 40 –
Trim Cylinder
1. Install a new lubricated O‑ring onto the memory piston.
a - Memory piston
b - O‑ring
a
b
48711
2. Install new lubricated O‑rings onto the end cap and shock piston.
a b a - End cap O‑ring

b - Shock piston O‑ring
70670
3. Place the memory piston into the cylinder bore.

4. Push the memory piston all the way to the bottom.
5. Fill the cylinder 75 mm (3 in.) from the top of the cylinder using Power Trim and Steering Fluid. If not available, use
automotive automatic transmission fluid (ATF).

114 Power trim system 92-858074K01
Fluid
6. Install the shock rod into the cylinder until the power trim fluid flows through the oil blow off the ball passage.
7. Fill the cylinder to just below the cylinder threads.
IMPORTANT: The end cap must not make contact with the shock rod piston when tightening. The shock rod piston must
be positioned in the cylinder deep enough to avoid contact.
8. Tighten the end cap securely using a spanner wrench (6.4 mm x 8 mm [1/4 in. x 5/16 in.] long pegs). If a torquing type
spanner tool is used to tighten the end cap, then tighten the end cap to the specified torque.


Power Trim

End cap 205 – 151.2

1. Lubricate the bushings with 2‑4‑C with PTFE.
2. Install the lower pivot bushings into the power trim unit.
70584

Power Trim System Installation

! WARNING
Damaged wires can cause electrical problems, resulting in system failure. In some cases, this can affect boat operation,
leading to personal injury. Use conduit, hose clamps, grommets, or other appropriate measures to protect all electrical wires.
Do not overtighten clamps and keep harnesses away from heat sources during installation.
1. Tilt the outboard to the full up position and support with the tilt lock lever.
2. Ensure that the flange bushings are installed in the upper pivot bore of the swivel bracket.
a a - Flange bushing
49432
3. Retract the trim cylinder rod approximately 5 cm (2 in.).

4. Position the power trim assembly, bottom first, between the transom brackets.

Power Trim
5. Route the trim pump electrical wires up, alongside of the starboard transom bracket.
48757
6. Lubricate the lower pivot pin with 2‑4‑C with PTFE.

7. Install one of the lower pivot pin washers onto the lower pivot pin. Secure with the M8 x 35 bolt.
a
b
49433
a - Lower pivot pin

b - Washer
c - Bolt (M8 x 35)
NOTE: The retaining bolt hole is not centered in the lower pivot pin.
8. Partially install the lower pivot pin into the transom bracket and power trim assembly. Rotate the pin until the washer is
centered with the counterbore in the transom bracket.
9. Use a suitable punch to drive the lower pivot pin into the bore until the washer is seated in the transom bracket
counterbore.

Power Trim
10. Install the opposite end retaining washer and bolt. Tighten the bolts to the specified torque.
a - Bolt (M8 x 35)

b - Washer
b
48570

95 2-4-C with PTFE Lower pivot pin 92-802859A 1

Bolt (M8 x 35) 22 – 16.2
11. Install the anode and ground cables onto the base of the power trim unit. Tighten the bolts to the specified torque.
a- Power trim unit

d b- Anode
c- Bolt (M6 x 25)
a d- Ground cable
c
b
48569

Bolt (M6 x 25) 8 70.8 –
12. Secure the power trim harness to the starboard transom bracket with a J‑clip and screw. Tighten the screw to the specified
torque.
a- Screw (M6 x 8)
b- J‑clip
c- Cable tie
a
d- Harness
b
c
d
48775

Power Trim

Screw (M6 x 8) 6 53.1 –
13. Route the trim harness through the trim harness retainer.
14. Push the harness through the grommet in the cowl.
a- Trim harness retainer

a
b- Trim harness
c- Grommet
b d- Screw
e- Ground cable
c
d
e
48562
15. Connect the trim wire harness connectors.

16. Connect the trim position sensor connector.
a - Trim wire harness connectors

b - Trim position sensor connector
48563
17. Extend the trim cylinder rod to align the power trim cylinder rod eye and the swivel bracket cross holes.
NOTE: Ensure that the threaded hole in the rod eye faces aft.
18. Insert the upper pivot pin through the swivel bracket and power trim cylinder rod eye.
IMPORTANT: The slotted end of the pivot pin faces starboard.
19. Insert a punch into the trim cylinder rod eye to align the hole with the threaded hole in the upper pivot pin.
20. Apply Loctite 242 Threadlocker to the threads of the upper pivot pin retaining screw.

Power Trim
21. Install the special screw into the upper pivot pin and trim cylinder rod eye.
a a- Upper pivot pin (slot is in line with cross hole)

b b- Hole in rod eye (faces aft)
c- Upper pivot pin retaining screw
c
d- Rod eye
d
48336

22. Tighten the upper pivot pin retaining screw to the specified torque.
a - Upper pivot pin retaining

c screw
b - Trim cylinder rod eye
d c - Upper pivot pin
d - Slotted end of pivot pin
b
48758

Upper pivot pin retaining screw 32 – 23.6
23. Install the trim position sensor with the potting side facing out and secure with two screws. Tighten the screws to the
specified torque.
IMPORTANT: The trim sensor must be installed with the potting side facing out. Newer design 2 sensors have locating
pins to ensure proper installation.
e a- Trim position sensor

b- Screw (2)
a c- Tilt lock knob
d- Tilt lock lever
b
e- Locating pins on design 2 trim
sensor
c
61803

Power Trim

Trim position sensor mounting screws 1.7 15 –
Trim Sensor
General Information
The digital trim sensor is mounted on the port side of the swivel bracket assembly. This sensor works off a magnet in the trim
rod pivot pin. A change in the trim position moves the pin, which changes the resistance value in the sensor. The trim sensor
value is displayed in counts in the CDS G3 Diagnostic Interface tool. The sensor is needed to limit the amount of trim at higher
speeds.
Trim Sensor Down Adaptation

The ECM learns the lowest trim sensor count number the first time the engine is trimmed to the full down position. This number
will be between 100–400 counts. Once the down number is learned, the maximum trim level above 2000 RPM will be limited to
220 counts above the adapted down number. For example, if your adapted down value is 180 counts and the maximum trim
limit is 220 counts above that number, your maximum trim will be 400 counts. The trim limit number of 220 counts can be set
lower by using the CDS G3 Diagnostic Interface tool. The trim limit cannot be set higher. The adapted trim down value may
change if the ECM learns a new lower number, but this will not change the maximum trim limit of 220 counts.
Trim down adapt range 100–400 counts

Maximum trim value above 2000 RPM 220 counts above the adapted down value
Maximum trim value below 2000 RPM No limit
Trim Sensor Down Adaptation Reset

With the engine trimmed to the full down position, the trim value should read 0% in the CDS G3 Diagnostic Interface tool. If the
down trim value does not read 0%, or if the trim value does not increase when trimming up, the down adaptation may need to
be reset. Replacing the trim sensor or removing the sensor with the key in the ON position can lead to this issue. To reset the
down trim value to 0%, follow these steps:
1. Turn the key to the ON position.
2. Trim the engine to the full down position.
3. Unplug the trim sensor and wait about 10 seconds for a trim sensor fault to occur. The horn should sound when the fault is
triggered.
4. Plug the trim sensor back in. The new down trim value should be 0%.

Power Trim
Notes:

Right-Hand Rotation
Gear Housing
Section 6A - Right-Hand Rotation
Table of Contents
Right‑Hand Gear Housing Specifications.......................... 6A-2 Propeller Shaft Dissassembly—with Dual Springs in
Gear Housing (Driveshaft)............................................... 6A-10 Actuator Rod......................................................... 6A-35
Gear Housing, Propeller Shaft, Standard Rotation Clutch Pinion Gear and Driveshaft Removal...............................6A-36
—Stamp 8M0045760................................................... 6A-12 Driveshaft Cleaning and Inspection.......................... 6A-38
Gear Housing, Propeller Shaft, Standard Rotation Clutch Forward Gear Disassembly............................................. 6A-38
—Stamp 8M0073249................................................... 6A-14 Cleaning and Inspection........................................... 6A-39
Gear Housing, Propeller Shaft, Standard Rotation— Gear Housing Inspection................................................. 6A-40
SeaPro......................................................................... 6A-16 Pinion Bearing Installation............................................... 6A-40
General Service Recommendations................................ 6A-18 Propeller Shaft Assembly.................................................6A-41
Bearings....................................................................6A-18 Propeller Shaft Assembly—without Dual Springs in
Shims........................................................................6A-18 Actuator Rod, Early Style Shift Cam and Follower
Seals.........................................................................6A-18 .............................................................................. 6A-41
Gearcase Removal ......................................................... 6A-19 Propeller Shaft Assembly—without Dual Springs in
6
XL Models with Spacer.................................................... 6A-21 Actuator Rod, Later Style Shift Cam and Follower
Gearcase Service Inspection........................................... 6A-21 .............................................................................. 6A-43
Draining and Inspecting Gear Housing Lubricant..... 6A-21 Propeller Shaft Assembly—with Dual Springs in
Draining and Inspecting Gear Housing Lubricant—
SeaPro Models......................................................6A-22
Actuator Rod......................................................... 6A-44
Bearing Carrier Assembly................................................ 6A-47
A
Propeller Shaft Inspection.........................................6A-22 Forward Gear Assembly.................................................. 6A-50
Water Pump Removal and Disassembly......................... 6A-23 Forward Gear Bearing Race Assembly........................... 6A-51
Cleaning and Inspection........................................... 6A-24 Driveshaft Assembly........................................................ 6A-52
Oil Seal Carrier Assembly................................................6A-26 Pinion Gear Depth........................................................... 6A-55
Removal....................................................................6A-26 Forward Gear Backlash................................................... 6A-57
Disassembly............................................................. 6A-27 Reverse Gear Backlash (Standard Rotation)...................6A-59
Bearing Carrier and Propeller Shaft Removal .................6A-27 Propeller Shaft Bearing Preload...................................... 6A-60
Shift Shaft Inspection................................................6A-30 Shift Shaft Installation...................................................... 6A-62
Bearing Carrier Disassembly........................................... 6A-30 Water Pump Assembly.................................................... 6A-65
Propeller Shaft Inspection and Disassembly................... 6A-32 Gear Housing Pressure Test........................................... 6A-67
Propeller Shaft Inspection.........................................6A-32 Gear Housing Installation.................................................6A-68
Propeller Shaft Disassembly—with Ball Bearings in Gear Lubricant Filling Instructions................................... 6A-71
Actuator Rod......................................................... 6A-33 Filling Gearcase—SeaPro Models...................................6A-71
Propeller Shaft Disassembly—without Dual Springs in
Actuator Rod......................................................... 6A-34

Right-Hand Rotation

Gear ratio (teeth) 150, 150 SeaPro 1.92:1 (13/25)
Reverse gear backlash 0.305–0.838 mm (0.012–0.033 in.)
Water pressure
At WOT 80–300 kPa (11.6–43.5 psi)

Extreme Grease Driveshaft splines and shift shaft splines 8M0071842
Outer diameter of all metal case oil seals
7 Loctite 271 Threadlocker Outside diameter of outer propeller shaft oil seal 92-809819
Threads of the pinion nut
Bearings
Inside diameter of the reverse gear ball bearing
Outside diameter of the propeller shaft needle bearing
Outside diameter of the reverse gear ball bearing
High-Performance Gear
87 Center bore of the forward gear 92-858064K01
Lubricant
Inside diameter of the forward gear tapered bearing
Inside diameter of driveshaft tapered bearing
Inside diameter of upper driveshaft tapered bearing
Gear housing
Use to ease installation of all O-rings, and to prevent wear, apply
on the I.D. of oil seals
Pinion bearing bore
Pocket on the cam follower
Oil seal lips and O-ring
Bearing carrier gear housing contact surfaces
95 2-4-C with PTFE 92-802859A 1
Outside diameter of forward gear bearing race
Bearing retainer
Shift shaft bushing O-ring and seal lip
Threads of the retainer nut
Driveshaft oil seal carrier O-ring and seal lips
Inside of water pump cover
117 Loctite 7649 Primer N Pinion nut threads 92-809824
134 Loctite 380 Black Max Outside diameter of shift shaft seal Obtain Locally
Special Tools
Dial Indicator 91‑ 58222A 1
Used to obtain a variety of measurements including gear backlash, pinion gear

location, and TDC.
9479

Right-Hand Rotation
Dial Indicator Adapter 91‑83155
Dial indicator holding fixture.

2999
Dial Indicator Holding Tool 91‑89897
Secures the dial indicator to gear housing when checking backlash.
29496
Bearing Carrier Retainer Nut Wrench 8M0057002
Installs and removes the bearing carrier retainer nut
46139
Puller Jaws Assembly 91‑46086A1
Removes bearing carrier and bearing races; use with Puller Bolt (91‑85716)
9514
Slide Hammer 91‑34569A 1
Aids in the removal of various engine components. Use with puller jaws.
6761
Universal Puller Plate 91‑37241
Removes bearings from gears and the driveshaft
8505

Right-Hand Rotation
Bearing Removal and Installation Kit 91‑31229A7

Installs and removes the bearings in all gearcases. All components can be
purchased separately.
91‑ 31229A 7 tool assembly includes the following components:
11‑ 24156 Hex Nut
12‑ 34961 Washer
91‑ 15755T Needle Bearing Driver
91‑ 29310 Plate
91‑ 30366T 1 Mandrel
91‑ 31229 Puller Shaft
91‑ 32325T Driver Head
91‑ 32336 Needle Bearing Driver
91‑ 36379 Puller and Head Gear
91‑ 36571T Pilot Washer
91‑ 37292 Roller Bearing
91‑ 37311 Driver Head
2966 91‑ 37323 Driver Head Rod
91‑ 37350T Pilot Mandrel
91‑ 38628T Puller and Driver Head
91‑ 52393T Pinion Bearing Installation Tool
91‑ 52394 Head Pull Rod
Actuator Assembly Tool 91‑8M0057704
Aids in the installation of the shift actuator rod

48577
Pin Stop Installation Tool 91‑8M0045644
Part of tool assembly 91‑8M0057704

48578
Pin Pull Tool 91‑8M0045645

49768
Driveshaft Bearing Retainer Wrench 91‑43506T
Removes and installs the threaded bearing retainer
9520
Driveshaft Holding Tool 91‑889958T
Holds driveshaft while removing or installing pinion nut.
28677
Driver Rod 91‑37323
25431 Aids in the removal and installation of various bearings and bearing races

Right-Hand Rotation
Bearing Driver Tool 91‑8M0062360
Removes pinion bearing from gear housing
49079
Pilot Washer 91‑36571T
Used in pinion gear and pinion bearing installation
29490
Beveled Cross Pin Tool 91‑8M0045643
Aids in the installation of the sliding clutch cross pin

48579
Needle Bearing Driver 91‑15755T
Installs needle bearings into bearing carriers
10787
Oil Seal Driver 91‑31108T
Installs bearing carrier oil seals
8883
Torch Lamp Obtain Locally
Heats surfaces to aid in the removal and installation of interference fit engine
components
8776
Mandrel 91‑8M0077816
Installs the needle bearing into the forward gear
48574

Right-Hand Rotation
Bearing Cup/Adapter Installation Tool 91‑8M0057767
Installs the forward gear bearing race on the standard right‑hand gear case.
Presses the reverse gear bearing adapter into the gear housing on the counter
left‑hand gear case
49261
Pilot Ring 91‑8M0074763
Aligns the bearing cup installation tool in the gearcase bore
56249
Retainer Installer Tool 91‑8M0074757
Maintains the alignment of the driver tool.
56237
Bearing Cup Driver 91‑8M0077786
Installs the forward gear bearing cup

9445
Driveshaft Bearing Installation Tool 91‑8M0052590
Install upper and lower driveshaft bearings
47416
Bearing Preload Tool 91‑14311A04
Simulates a load on the driveshaft for accurate pinion height and backlash
measurements
8756

Right-Hand Rotation
Pinion Gear Locating Tool 91‑8M0089163
Measures pinion gear height

B A
56235
Pinion Gear Locating Tool Upgrade Kit 91‑8M0089165
Upgrades previous pinion gear locating tool kit P/N 91‑8M0057712 to current
P/N 91‑8M0089163 components.
60578
Pinion Gauge Adapter Tool 91‑8M0070993
Allows pinion locating gauge to adapt to various front gear bearings. Tool is
included with pinion gear locating tool P/N 91‑8M0089163 and pinion gear
locating tool upgrade kit P/N 91‑8M0089165.
56254
Locating Disc #4 91‑8M0060656
Provides an access hole to measure the pinion depth. Tool is included with
pinion gear locating tool P/N 91‑8M0089163 and pinion gear locating tool
upgrade kit P/N 91‑8M0089165.
49549
Backlash Indicator Rod 91‑8M0053505
Aids in checking gear backlash

9450
Propeller Shaft/Driveshaft Adapter 91‑61077T
Provides a hex surface to turn the propeller shaft. For use with (15 spline) 1‑3/16
inch prop
10805
Bearing Carrier Retainer Nut Wrench 91‑8M0057002
46139

Right-Hand Rotation
Driveshaft Seal Installation Tool 91‑818769
Sets driveshaft seal to proper height over water pump cover. Tool is included
with various water pump kits. Save tool for future use.
47536
Used for pressure testing of closed systems (gear housing, fuel lines, cooling).
29497

Right-Hand Rotation
Notes:

Right-Hand Rotation
Gear Housing (Driveshaft)

42
11
42
12
14 10
13
31 15
16
17
18
19
34
40
20
21
6
22
35 32
37 23
36 41
38 33
43
39 24
8 7 5
25
26
4
7 27
9 28
29
44 30
23
1
45 3
48386

Right-Hand Rotation

Torque
1 1 Gearcase
2 1 Plug
3 2 Seal
4 1 Dowel pin with hole (0.375 x 0.625)
5 1 Dowel pin without hole (0.375 x 0.625)
6 1 Roller bearing assembly
7 2 Anode
8 1 Screw (M6 x 40) 6.8 60.2 –
9 1 Stainless steel nut (M6) 6.8 60.2 –
10 1 Filler block
11 1 Water pump coupler
12 4 Screw (M6 x 20) 6.8 60.2 –
13 1 Water pump cover
14 1 V‑ring face seal
15 1 Drive key
16 1 Impeller
17 1 Gasket
18 1 Faceplate
19 1 Gasket
20 1 Retaining ring
21 1 Oil seal carrier assembly
22 2 Oil seal
23 1 O‑ring (2.175 x 0.103)
24 1 Retainer 135.5 – 100
25 1 Tapered roller bearing cup
26 1 Tapered roller bearing cone
27 1 Shim
30 1 Shim
31 1 Driveshaft
32 1 Pinion gear
33 1 Nut (0.625‑18) 101.7 – 75
34 1 Shift shaft
35 1 Retaining ring
36 1 Oil seal
37 1 Washer
38 1 Bushing assembly
39 1 O‑ring
40 1 E‑ring
41 1 Washer
42 2 O‑ring (0.796 x 0.139)
43 1 Screw (0.437‑14 x 1.750) 54 – 39.8
44 1 Anode
45 1 Vent screw 11.3 100 –

Right-Hand Rotation
Gear Housing, Propeller Shaft, Standard Rotation Clutch—Stamp 8M0045760
1
16 17
14 15
11 12
9 10 13
2 8
3
5 4
6
7 31
30
29
28
27
24
23
22
21 25
20 26
19
18
48387

Right-Hand Rotation

Torque
1 1 Gear housing
2 1 Forward gear
3 1 Needle bearing
4 1 Retaining ring
7 1 Shim
8 1 Cam follower
9 1 Shift cam
10 1 Clutch actuator rod
11 2 Ball bearing (0.250 in. diameter)
12 1 Compression spring (0.305 in. O.D.)
13 1 Ball bearing (0.3125 in. diameter)
14 1 Retaining spring
15 1 Six jaw sliding clutch
16 1 Cross pin
17 1 Propeller shaft
18 1 Spacer
19 1 Reverse gear
20 1 Ball bearing
21 1 Thrust ring
22 1 O‑ring (3.975 x 0.210)
23 1 Bearing carrier
24 1 Needle bearing
25 1 Fill screw 11.3 100 –
26 1 Seal
27 1 Seal
28 1 Seal
29 1 Tab washer
30 1 Retainer 285 – 210.2
31 1 Propeller bore sleeve

Right-Hand Rotation
14
11
13
12
2
3
10 4
5
6
7 27
8 26
9 25
24
23
20
19
18
17 21
22
16
15
28
62368

Right-Hand Rotation

Torque
1 1 Gear housing
2 1 Forward gear
3 1 Needle bearing
4 1 Retaining ring
7 1 Shim
9 1 Cam follower
10 1 Shift cam
11 1 Sliding clutch
12 1 Cross pin
13 1 Spring
15 1 Reverse gear
16 1 Ball bearing
17 1 Thrust ring
18 1 O‑ring
19 1 Bearing carrier spool
20 1 Needle bearing
21 1 Fill screw 11.3 100 –
22 1 Seal
23 1 Oil seal
24 1 Seal
25 1 Tab washer
26 1 Bearing carrier retainer 285 – 210.2
28 1 Spacer

Right-Hand Rotation
Gear Housing, Propeller Shaft, Standard Rotation—SeaPro
1
29
14
28
11
13
12
2
3
10 4
5 27
6
7 26
8
25
9
24
23
34 31
33 30 20
32 19
18
21
17 22
16
15
35
58603

Right-Hand Rotation
Gear Housing, Propeller Shaft, Standard Rotation—SeaPro

Torque
1 1 Gear housing
2 1 Forward gear
3 1 Needle bearing
4 1 Retaining ring
7 1 Shim
9 1 Cam follower
10 1 Shift cam
11 1 Sliding clutch
12 1 Cross pin
13 1 Spring
15 1 Reverse gear
16 1 Ball bearing
17 1 Thrust ring
18 1 O‑ring
19 1 Bearing carrier spool
20 1 Needle bearing
21 1 Fill screw 11.3 100 –
22 1 Seal
23 1 Oil seal
24 1 Seal
25 1 Tab washer
28 1 Magnetic drain screw
29 1 Seal
30 1 Actuator kit (2B384875 and up)
32 1 Cross pin
33 2 Spring
34 1 Pin
35 1 Spacer

Right-Hand Rotation
General Service Recommendations

There may be more than one way to disassemble or assemble a particular part. It is recommended the entire procedure be
read prior to repair.
Disassembly of a subassembly may not be necessary until cleaning and inspection reveals that disassembly is required for
replacement of one or more components.
Service procedure order in this section is a normal disassembly/assembly sequence. The sequence should be followed without
deviation to assure proper repairs. When performing partial repairs, follow the instructions to the point where the desired
component can be replaced, then proceed to assembly and installation of that component in the assembly part of this section.
Use the Table of Contents to find the correct page number.
mandrel that will contact only the bearing race when pressing or driving bearings.
Bearings
Upon disassembly of the gear housing, all bearings must be cleaned and inspected. Clean the bearings with solvent and dry
with compressed air. Air should be directed at the bearing so that it passes through the bearing. Do not spin the bearing with
compressed air, as this may cause the bearing to score from lack of lubrication. After cleaning, lubricate the bearings with
High‑Performance Gear Lubricant. Do not lubricate the tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches, and bearing race side wear. Work the inner bearing race in and out, while holding
the outer race, to check for side wear.
When inspecting the tapered bearings, determine the condition of the rollers and the inner bearing race by inspecting the
bearing cup for pits, scoring, grooves, uneven wear, imbedded particles, and/or discoloration from overheating. Always replace
the tapered bearing and race as a set.
Inspect the gear housing for bearing races that have spun in their respective bores. If the race has spun, the gear housing must
be replaced.
Roller bearing condition is determined by inspecting the bearing surface of the shaft that the roller bearing supports. Check the
shaft surface for pits, scoring, grooves, imbedded particles, uneven wear, and/or discoloration from overheating. The shaft and
bearing must be replaced if the conditions described are found.

87 Bearings 92-858064K01
Lubricant
Shims
Keep a record of all shim amounts and their location during disassembly to aid in assembly. Be sure to follow the shimming
instructions during assembly, as gears must be installed to the correct depth and have the correct amount of backlash to avoid
noisy operation and premature gear failure.
Seals
As a normal procedure, all O‑rings and oil seals should be replaced without regard to appearance. To prevent leakage around
oil seals, apply Loctite 271 Threadlocker to the outer diameter of all metal case oil seals. When using Loctite on seals or
threads, the surfaces must be clean and dry. To ease installation, apply 2‑4‑C with PTFE on all O‑rings. To prevent wear, apply
2‑4‑C with PTFE on the l.D. of oil seals.

7 Loctite 271 Threadlocker Outer diameter of all metal case oil seals 92-809819
Use to ease installation of all O-rings, and to prevent wear,
95 2-4-C with PTFE 92-802859A 1
apply on the I.D. of oil seals

Right-Hand Rotation
Gearcase Removal
! WARNING
1. Disconnect both battery leads from the battery.

2. Shift the gearcase into neutral position.
3. Tilt the engine up and engage tilt lock lever.
4. Bend the tabs of the propeller tab washer away from the thrust hub and remove the propeller locknut, tab washer,
propeller, and thrust hub from the propeller shaft.
b a- Tab washer
a b- Continuity washer (if equipped)
f
c- Propeller locknut
d- Rear thrust hub
e- Propeller shaft
f- Front thrust hub
d c e
48808
5. Mark the position of the trim tab, if equipped, so it can be installed in the same position.
6. Remove the rubber cover at the rear edge of the driveshaft housing.
a - Rubber cover
48235
NOTE: For XL gearcases, there may be a spacer installed below the driveshaft housing assembly.
7. Remove the screw securing the anodic plate, or trim tab if equipped, and remove the anodic plate.

Right-Hand Rotation
8. Remove the screw from the inside of the anodic plate cavity.
a - Screw
48236
9. Loosen the side mounting locknuts.
NOTE: Do not attempt to remove one locknut before the opposite side mounting locknut is loosened.
a - Locknuts and washers (two each side)
48245
10. Pull the gear housing away from the driveshaft housing as far as the loosened locknuts will allow and remove the locknuts.
11. Pull the gear housing from the driveshaft housing.
IMPORTANT: On models that have the 5 in. spacer, the driveshaft housing spacer will release with the gearcase during
removal. The use of masking tape to secure the spacer to the gearcase during removal will prevent the spacer from falling
off.

Right-Hand Rotation
XL Models with Spacer

2
3
6 3
1
4
4
5
4
5
5
71422
Torque
1 1 Driveshaft housing spacer
2 2 Dowel pin
3 4 M12 x 1.75 x 179 double ended stud 30 – 22.1
4 5 Washer
5 5 M12 hex locknut 60 – 44.2
6 1 Screw M12 x 160 30 – 22.1
Gearcase Service Inspection

Draining and Inspecting Gear Housing Lubricant
1. Place the gear housing in a suitable holding fixture or vise with the driveshaft in a vertical position.

Right-Hand Rotation
2. Position a clean drain pan under the gear housing and remove the fill and vent screws from the gear housing.
a - Fill screw
b - Vent screw
a
48252
3. Inspect the gear lubricant for metal particles. Presence of a small amount of fine metal particles resembling powder
indicates normal wear. Presence of larger particles, or a large quantity of fine particles, indicates the gear housing should
be disassembled and inspected.
4. Note the color of the gear lubricant. White or cream color indicates the presence of water in the lubricant. Check the drain
pan for water separation from the lubricant. Presence of water in the gear lubricant indicates the gear housing should be
disassembled and inspected.
Draining and Inspecting Gear Housing Lubricant—SeaPro Models

a b
62153
a - Upper vent plug

Propeller Shaft Inspection

1. Install the dial indicator adapter to the gearcase and attach the dial indicator.
2. Rotate the propeller shaft while observing the dial indicator. If the runout is more than 0.152 mm (0.006 in.), a bent
propeller shaft is indicated.

Right-Hand Rotation
3. Check the propeller shaft for axial end play. End play should be 0.127–1.905 mm (0.005–0.075 in.).
c
a - Propeller shaft
b - Propeller shaft end play
a
c - Dial indicator, checking for runout
61902
Propeller Shaft
Runout 0.152 mm (0.006 in.)
End play 0.127–1.905 mm (0.005–0.075 in.)

Water Pump Removal and Disassembly

1. Remove the water tube coupler.
2. Slide the V‑ring face seal off the driveshaft.
3. Remove and retain the four screws securing the water pump cover to the gear housing.
4. Lift the water pump cover off the driveshaft.
NOTE: If tools are used to pry the water pump cover up, protect the surface of the gearcase where the tools contact to
prevent damage to the paint which may result in future corrosion.
a- Water tube coupler

b- V‑ring face seal
c- Water pump cover
a b c d- Screws (M6 x 20) (2 each side)
d
55949
5. Remove the impeller from the driveshaft.

NOTE: It may be necessary to use a hammer and chisel to remove the impeller or split the hub of the impeller.
6. Remove the impeller drive key from the driveshaft.

Right-Hand Rotation
7. Remove the water pump faceplate.
a - Impeller
b - Drive key
c - Faceplate with molded gasket
a
c b
55950
NOTE: The overmolded water pump faceplate design has been replaced with a three‑piece faceplate and gaskets design.
Remove the water pump faceplate, and both gaskets, if equipped.
a
Three-piece faceplate and gaskets
a - Fiber gasket (silicone sealing bead faces up)
b - Faceplate
c - Metal gasket
48269
Cleaning and Inspection

1. Inspect the rubber sealing surfaces on the water tube coupler assembly. Replace the coupler if damaged.
2. Inspect the faceplate for grooves or rough surfaces. Inspect the overmolded gasket material for damage.

Right-Hand Rotation
IMPORTANT: The circular groove on the faceplate formed by the impeller will not affect the water pump output.
a b c
55951
Single-piece overmolded gasket

a - Water pump impeller side of faceplate
b - Overmolded gasket material
c - Bottom side overmolded gasket material
NOTE: A damaged overmolded faceplate will be replaced by the new three‑piece faceplate and gaskets design. Inspect
the new three‑piece face plate and gaskets design as follows.
a. Inspect the stainless steel gasket coated surface for scratches or damage. If the coating is scratched or damaged,
replace the stainless steel gasket.
a - Stainless steel gasket

a
b - Coating
b
46007
b. Inspect the faceplate for grooves or rough surfaces. Replace the faceplate if damage is found.
c. Inspect the fiber gasket. Replace the fiber gasket if damage is found.
3. Inspect the water pump liner for grooves or rough surfaces.
55952
4. Inspect the impeller seal surfaces and the ends of the impeller blades for cracks, tears, and wear. Replace the impeller if
any of these conditions are found.

Right-Hand Rotation
5. Inspect the keyway and impeller bonding to the impeller hub.
b a - Impeller
a b - Keyway/impeller hub
55953
6. Inspect the impeller for glazed or melted appearance caused by operation without sufficient water supply. Replace the
impeller if any of these conditions are found.
IMPORTANT: When completing gear housing repairs that require removal of the water pump impeller, it is recommended
the impeller be replaced. However, if the impeller must be used, do not install in reverse to the original rotation; premature
impeller failure will occur.
Oil Seal Carrier Assembly

Removal
1. Remove the retaining ring securing the oil seal carrier.
a - Oil seal carrier

b - Retaining ring
48281
NOTE: When prying the oil seal carrier up, protect the surface of the gearcase where the tools contact to prevent damage
to the paint which may result in future corrosion.

Right-Hand Rotation
2. Use suitable tools to remove the oil seal carrier from the gearcase assembly.
c a - Oil seal carrier

b - Oil seal carrier pry points
c - Protective pad
a
c
b
48284
3. Remove and discard the O‑ring from the oil seal carrier.
NOTE: If the oil seals within the seal carrier require replacement, the oil seal carrier must be replaced as an assembly.
a a - Oil seal carrier

b - O‑ring
48291
Disassembly
NOTE: The oil seals within the oil seal carrier are not individually replaceable. If the oil seals require replacement, the oil seal
carrier must be replaced as an assembly.
Bearing Carrier and Propeller Shaft Removal

1. Place the gear housing in a suitable holding fixture with the propeller shaft in a horizontal position.
2. Use the shift shaft to shift the gear housing into neutral.
IMPORTANT: The gear housing must be in neutral before the propeller shaft can be removed.
3. Remove the gear housing oil fill screw.

Right-Hand Rotation
4. Bend the retainer nut lock tabs out of the retainer nut recesses.
a - Bearing carrier retainer nut

b - Propeller bore sleeve
c - Lock tabs
a
b
c
48306
5. Remove the gear housing retainer nut and propeller bore sleeve with the bearing carrier retainer nut wrench.
a - Bearing carrier retainer nut wrench
35528

6. Remove the locking tab washer from the gear housing.
a - Locking tab washer
48311
7. Verify that the gear housing is in neutral. Remove the shift shaft rubber washer and retaining ring.

Right-Hand Rotation
8. Remove the shift shaft and bushing.
a- Shift shaft
b- Shift shaft bushing
a
c- Rubber washer
b d- Retaining ring
d
c
55954
9. Remove and discard the shift shaft bushing O‑ring.
a - Shift shaft bushing O‑ring

a
48317
10. Use the long puller jaws and puller bolt to remove the bearing carrier.

Right-Hand Rotation
NOTE: Use the propeller thrust hub to maintain pressure on the puller jaws.
d
a
b
48555
a- Long jaws
b- Puller bolt
c- Thrust hub
d- Shift shaft bushing
e- Shift shaft

11. Remove the propeller shaft, cam follower, and shift cam by pulling the propeller shaft straight out of the gear housing. Do
not jerk the propeller shaft out of the gear housing. If the propeller shaft will not come out, proceed as follows:
• Push the propeller shaft back into place against the front gear. Visually inspect the location of the shift cam by looking
down the shift shaft hole. If the splined hole in the shift cam is visible, install the shift shaft and rotate the shift shaft
into the neutral position. Remove the shift shaft and then remove the propeller shaft.
Shift Shaft Inspection

1. Clean the shift shaft and bushing with a mild solvent and dry with compressed air.
2. Check the shift shaft splines for wear, corrosion, or damage.
3. Inspect the shift shaft for grooves at the seal area.
4. Inspect the bushing for damage.
5. If any of these conditions exist, replace the shift shaft.
Bearing Carrier Disassembly

1. Remove and discard the O‑ring on the bearing carrier.
2. Secure the bearing carrier in a soft jaw vise.
IMPORTANT: Clamp on the raised reinforcing rib on the bearing carrier when securing the carrier in a vise to prevent
damage to the carrier.

Right-Hand Rotation
3. Use a slide hammer to remove the reverse gear assembly.
e a- Bearing carrier
c b- O‑ring
b d c- Spacer
d- Reverse gear
e- Slide hammer
a
f- Raised reinforcing rib
48321
f
4. Use the universal puller plate and a suitable mandrel to press the gear off the bearing.
5. If the reverse gear bearing remained in the bearing carrier, use the slide hammer to remove the bearing.
a- Universal puller plate

b- Bearing
c- Gear
d d- Mandrel
b
c
33975

6. Inspect the reverse gear to pinion gear wear pattern. It should be even and smooth. If not, replace the reverse gear, pinion
gear, and forward gear.
7. Inspect the reverse gear for pitted, chipped or broken teeth, and hairline fractures. Replace the reverse gear and the pinion
gear if any defects are found.

Right-Hand Rotation
8. Check the clutch jaws on the reverse gear for damage. Replace the reverse gear if damage is found.
b a - Reverse gear
b - Clutch jaws
a
49529
9. Remove the propeller shaft oil seals with a pry bar or slide hammer.
NOTE: Do not damage the inside diameter of the bearing carrier when removing the propeller shaft seals.
10. Press the propeller shaft needle bearing out of the bearing carrier with a suitable mandrel.
d 35535
a- Pry bar
b- Propeller shaft needle bearing
c- Mandrel
d- Oil seals
Propeller Shaft Inspection and Disassembly

1. Clean the propeller shaft assembly with solvent and dry with compressed air.
2. Inspect the propeller shaft bearing carrier oil seal surface area for grooves. Replace the shaft if grooves are found.
3. Visually inspect the bearing surfaces of the propeller shaft for pitting, grooves, scoring, uneven wear, or discoloration from
overheating. Replace the shaft and corresponding needle bearing if any of the previous mentioned conditions are found.
4. Inspect the propeller shaft splines for wear and/or corrosion damage.
5. Check the propeller shaft for runout.

Right-Hand Rotation
a. Position the propeller shaft roller bearing surfaces on V‑blocks. Use a dial indicator at the front edge of the propeller
splines. Rotate the propeller shaft. Dial indicator movement more than the specification requires the propeller shaft to
be replaced.
a - V‑blocks
b - Bearing surfaces
b c - Dial indicator location
b
a
c
61909
Propeller Shaft
Runout 0.152 mm (0.006 in.)

6. Inspect the sliding clutch jaws. Rounded clutch jaws indicate one or more of the following conditions:
• Improper shift cable adjustment
• Improper shifting technique ‑ shifting too slow
• Engine RPM too high while shifting
a b a - Reverse gear clutch dog teeth

b - Forward gear clutch dog teeth
48326
Propeller Shaft Disassembly—with Ball Bearings in Actuator Rod

1. Remove the shift cam from the cam follower.
2. Insert a thin blade screwdriver or awl under the first coil of the retaining spring and rotate the propeller shaft to unwind the
spring from the clutch. Do not overstretch the spring.
c
a- Cam follower
a b- Shift cam
c- Cross pin retaining spring
d- Awl
d 61910
3. Push the cross pin out of the sliding clutch and propeller shaft with the actuator assembly tool.

Right-Hand Rotation
NOTE: If either end of the actuator assembly tool is lost, the long threaded pull pin can be ordered through part number
91‑8M0045645. The short pin stop end can be ordered through part number 91‑8M0045644.
a a - Actuator assembly tool

b - Cross pin
b 48328

4. Remove the cam follower and clutch actuator rod from the propeller shaft.
d e f
a c g h
b
48331
a- Sliding clutch
b- Cross pin
c- Propeller shaft
d- Compression spring
e- Ball bearing, 7.94 mm (0.3125 in.) diameter
f- Clutch actuator rod
g- Ball bearing, 6.4 mm (0.250 in.) diameter (2)
h- Cam follower
NOTE: The compression spring and ball bearings (items d, e, and g) were removed from production and should be
discarded during disassembly, and not reused.
5. Remove the sliding clutch from the propeller shaft.
6. Clean the clutch actuator rod and cam follower in a mild solvent. Dry with compressed air and inspect the components for
wear or damage. Replace worn or damaged components.
Propeller Shaft Disassembly—without Dual Springs in Actuator Rod


Right-Hand Rotation
spring from the clutch. Do not overstretch the retaining spring.
a a - Cross pin retaining spring

b - Awl
c - Shift cam
c
b 55617
3. Push the cross pin out of the sliding clutch and propeller shaft.
a - Cross pin
a
55618
a- Sliding clutch
b- Cross pin
c- Propeller shaft
d- Clutch actuator rod
e- Cam follower
a d e
c
b
55619

6. Clean the clutch actuator rod and cam follower in a mild solvent. Dry with compressed air and inspect the components for
wear or damage. Replace worn or damaged components.
Propeller Shaft Dissassembly—with Dual Springs in Actuator Rod

a a - Cross pin retaining spring

b - Awl
c - Shift cam
c
b 55617

Right-Hand Rotation
3. Push the cross pin out of the sliding clutch and propeller shaft.
a - Cross pin
a
55618
f g a- Sliding clutch
b- Cross pin
c- Propeller shaft
d- Clutch actuator rod
e- Cam follower
f- Spring‑retaining cross
a pin
d e g - Springs (2)
c
b
60652
5. Remove the actuator rod from the cam follower. Remove the spring‑retaining cross pin from the clutch actuator rod and
remove the springs.
7. Clean the cam follower, and the clutch actuator rod and components in a mild solvent. Dry with compressed air and inspect
the components for wear or damage. Replace worn or damaged components.
Pinion Gear and Driveshaft Removal

1. Use the driveshaft bearing retainer wrench to remove the driveshaft bearing retainer.
a - Bearing retainer
b - Driveshaft bearing retainer wrench
48340

2. Install the driveshaft holding tool onto the driveshaft splines.

3. Use a 7/8 in. socket and flex handle to hold the pinion nut.
NOTE: Use a rag to protect the gear housing from damage.
4. Use the driveshaft holding tool to loosen the pinion nut.

Right-Hand Rotation
5. Remove the pinion nut and the driveshaft holding tool.
6. Remove the driveshaft by pulling the driveshaft straight out of the gear housing.
7. If the pinion gear is seized onto the driveshaft, clamp the driveshaft in a soft jaw vise.
8. Place a block of wood on the gear housing mating surface. Use a mallet and carefully tap the gear housing away from the
driveshaft.
IMPORTANT: Striking a gear housing directly with a mallet can distort the gear housing causing gear housing failure.
IMPORTANT: The pinion bearing rollers can fall out of the pinion bearing race after the driveshaft is removed. Do not lose
the 18 rollers.
a - Wood block
b - Soft jaw vise covers
b a
48341
9. Remove the pinion gear and forward gear assembly from the gear housing.
10. Remove the driveshaft tapered bearing shims and record the total dimension.
NOTE: Do not proceed with removing the bearings from the driveshaft unless they are damaged. Refer to Driveshaft
Cleaning and Inspection.
11. Install the universal puller plate.
12. Position the driveshaft in the vise as shown. Do not tighten the vise jaws directly against the driveshaft. Use soft jaw vise
covers.
13. Strike the driveshaft with a dead‑blow hammer to remove the upper driveshaft bearing.
14. Repeat the procedure to remove the lower bearing.
a - Upper bearings
b - Universal puller plate
c - Lower bearing (hidden)
a
56202

15. Install the pinion bearing rollers if they have fallen out. All of the rollers must be installed to remove the pinion bearing race.
16. Install the bearing driver tool into the pinion bearing and insert the driver rod into the gearcase and mandrel.
17. Install the pilot washer over the driver rod and into the gear housing to align the removal tools.
18. Use a hammer to remove the pinion bearing and discard the pinion bearing.

Right-Hand Rotation
19. Inspect the pinion gear for pitting, grooves, scoring, uneven wear, or discoloration from overheating. Replace the pinion
gear set if any of these conditions are found.
a - Bearing driver tool

b - Pilot washer
c - Driver rod
48344

Driveshaft Cleaning and Inspection

1. Clean all parts with a suitable solvent and dry with compressed air. Do not spin the bearings.
! WARNING
Spin‑drying bearings with compressed air can cause serious injury or death. The bearings can explode, even if spun at very
slow speeds. Do not allow the bearings to spin when drying with compressed air.
2. Inspect the driveshaft bearing cups for pitting, grooves, uneven wear, discoloration, or embedded particles. Replace the
bearings and bearing cups if any of these conditions are found.
3. Inspect the driveshaft pinion bearing surface area for pitting, grooves, scoring, uneven wear, or discoloration. Replace the
driveshaft if any of these conditions are found.
4. Inspect the splines at both ends of the driveshaft for a worn or twisted condition. Replace the driveshaft if any of these
conditions are found.
5. Inspect the driveshaft water pump base oil seal area for grooves. Replace the driveshaft if grooves are found.
b a - Splines
a c a
b - Pinion bearing surface
c - Seal contact area
56198
Forward Gear Disassembly

1. Remove the retaining ring securing the propeller shaft needle bearing.
2. Place the forward gear, with the teeth side up, into a soft jaw vise.

Right-Hand Rotation
3. Use a punch and hammer to remove the propeller shaft needle bearing and discard the bearing.
b 35566
a - Retaining ring
b - Bearing
4. Install the universal puller plate between the forward gear and tapered bearing.
5. Press the gear off the bearing with a suitable mandrel. Discard the bearing.
6. Remove the forward gear tapered bearing race from the gear housing with a slide hammer and retain the shims that are
behind the forward gear tapered bearing race.
b
c
a
d 35562

b- Mandrel
c- Slide hammer
d- Tapered bearing race


1. Clean the forward gear with a mild solvent and dry with compressed air. Do not spin the bearings.
! WARNING

Right-Hand Rotation
2. Inspect the gear teeth for pitting, grooves, scoring, uneven wear, and discoloration. Replace the gear if any of these
3. Inspect the clutch dogs for damage. Replace the gear if damage is found.
Gear Housing Inspection

1. Clean the gear housing thoroughly with a suitable solvent and a hard bristle brush. Dry the gear housing thoroughly using
compressed air. Ensure all sealants, locking agents, and debris are removed.
2. Verify the two oil circulation holes in the driveshaft bore and the shift shaft hole are clear and free of debris.
3. Inspect the gear housing for excessive corrosion, impact, or any other damage. Excessive damage and/or corrosion
requires replacement of the gear housing.
4. Inspect the bearing carrier retainer threads in the gear housing for corrosion and/or stripped threads. Damage or corrosion
to the threads requires replacement of the gear housing.
NOTE: The upper and lower driveshaft bearing cups are a slip fit within the driveshaft bore and may show signs of
movement. All other bearing cups are press fit and should not show any signs of movement.
5. Inspect bearing race/cup contact areas for evidence of bearing cup spinning. Check that bearing cups are not loose in
bearing bores. A press fit type bearing bore in which the race/cup is loose will require replacement of the gear housing.
6. Inspect for blockage in water inlet holes and the speedometer hole, clean as necessary. Be careful not to enlarge the
speedometer hole, as this could cause erroneous speedometer readings.
a
a - Oil circulation holes
b - Speedometer hole
c - Water inlet holes
49365
7. Verify the locating pins are in place in the gear housing and the corresponding holes in the driveshaft housing are not
elongated. The driveshaft may break if the housings are not aligned properly due to missing locating pins or elongated
holes.
Pinion Bearing Installation

IMPORTANT: Never install a pinion bearing that was removed from a gear housing. Always install a new pinion bearing.
1. Lubricate the gear housing pinion bearing bore with 2‑4‑C with PTFE.
2. Install the pinion bearing onto the mandrel so the letter and number side of the bearing is facing up.
3. Insert the mandrel and bearing into the gear housing pinion bearing bore.
4. Install the puller plate onto the puller rod and insert the puller rod into the gear housing driveshaft bore. Thread the puller
rod into the mandrel.

Right-Hand Rotation
5. Secure the puller rod and tighten the nut until the mandrel contacts the gear housing.
a- Puller rod
b- Puller plate
a c- Pilot washer
d- Pinion bearing (letters/numbers face up)
f e- Mandrel
b f- Hex nut
e
48970

95 2-4-C with PTFE Pinion bearing bore 92-802859A 1
Propeller Shaft Assembly

Propeller Shaft Assembly—without Dual Springs in Actuator Rod, Early Style Shift Cam
and Follower
1. Install the clutch onto the propeller shaft while aligning the cross pin hole in the clutch with the cross pin slot in the propeller
shaft.
a b c d a- Propeller shaft
b- Cross pin slot
c- Clutch
d- Cross pin hole
55699
2. Install the cam follower onto the actuator rod end.
a b a - Actuator rod
b - Cam follower
61911

Right-Hand Rotation
3. Align the cross pin opening in the actuator rod with the cross pin hole in the clutch. Insert the clutch actuator rod assembly
into the end of the propeller shaft. Position the actuator rod far enough into the propeller shaft to align the hole in the
actuator rod with the cross pin hole in the clutch. Install the cross pin through the clutch, actuator rod, and propeller shaft.
a b c e
d a- Propeller shaft
b- Clutch
c- Cross pin hole
d- Actuator rod
e- Cam follower
f- Cross pin
61912
4. Install the retaining spring to retain the cross pin. Do not allow the spring coils to overlap each other.
b a - Clutch
a
b - Cross pin (hidden)
c - Retaining spring
c 48438
5. Lubricate the pocket on the cam follower with 2‑4‑C with PTFE. This will help retain the shift cam onto the cam follower.
6. Install the shift cam into the cam follower pocket as shown.
a - Shift cam
95
b - Cam follower
b
a 48439

95 2-4-C with PTFE Pocket on the cam follower 92-802859A 1

Right-Hand Rotation
Propeller Shaft Assembly—without Dual Springs in Actuator Rod, Later Style Shift Cam
and Follower
shaft.
b- Cross pin slot
c- Clutch
d- Cross pin hole
55699
b - Cam follower
55622
3. Align the cross pin opening in the actuator rod with the cross pin hole in the clutch. Insert the clutch actuator rod assembly
into the end of the propeller shaft. Position the actuator rod far enough into the propeller shaft to align the hole in the
actuator rod with the cross pin hole in the clutch. Install the cross pin through the clutch, actuator rod, and propeller shaft.
a b c e
d a- Propeller shaft
b- Clutch
c- Cross pin hole
d- Actuator rod
e- Cam follower
f- Cross pin
f
55626
a b a - Clutch
c
55630

Right-Hand Rotation
a - Shift cam
a b
b - Cam follower
55631

Propeller Shaft Assembly—with Dual Springs in Actuator Rod

1. Insert the two compression springs into the clutch actuator rod and secure with the spring locating pin.
c
a
60664
a - Clutch actuator rod

b - Compression springs (2)
c - Spring locating pin

Right-Hand Rotation
2. Use a beveled cross pin tool to separate the two compression springs. Install the pin stop installation tool into the actuator
rod using the actuator assembly tool and mallet. Unscrew the pin pull tool from the pin stop installation tool. The pin stop
installation tool should remain in the actuator, separating the two compression springs.
d
a
c d c
b
60666
a- Actuator rod
b- Beveled cross pin tool
c- Pin stop installation tool (part of actuator assembly tool)
d- Pin pull tool (part of actuator assembly tool)

b - Cam follower
60653
shaft.
b- Cross pin slot
c- Clutch
d- Cross pin hole
55699
5. Insert the clutch actuator rod/cam follower assembly into the end of the propeller shaft. Position the actuator rod far enough
into the propeller shaft to align the pin stop installation tool in the actuator rod with the cross pin hole in the clutch.
b c a- Propeller shaft
a d e f
b- Clutch
c- Cross pin hole
d- Pin stop installation tool
(in actuator rod)
e - Actuator rod
f - Cam follower
60671

Right-Hand Rotation
6. Insert the pin pull tool into the cross pin hole and thread into the pin stop installation tool.
7. Turn the propeller shaft/clutch assembly over and insert the cross pin into the open cross pin hole in the clutch. Align the
cross pin so the flat surfaces of the pin will contact each compression spring in the actuator rod. Using a mallet, drive the
cross pin into the hole until it is fully seated in the clutch housing, and the actuator assembly tool falls from the clutch
assembly.
a
b
c
a a
60668
a - Pin pull tool (part of actuator assembly tool)

b - Cross pin
c - Pin stop installation tool (part of actuator assembly tool)

8. Install the retaining spring to secure the cross pin. Do not allow the spring coils to overlap each other.
a b a - Clutch
c
55630
a - Shift cam
a b
b - Cam follower
55631


Right-Hand Rotation
Bearing Carrier Assembly

1. Place the reverse gear on a press with the gear teeth facing down.
2. Place the thrust washer over the gear.
3. Apply High‑Performance Gear Lubricant onto the inside diameter of the reverse gear ball bearing and position the ball
bearing onto the gear with the numbered side of the bearing facing up.
4. Press the ball bearing onto the gear with a suitable mandrel until seated. Press only on the inner race of the bearing.
b a - Thrust washer
b - Mandrel
39699

87 Inside diameter of the reverse gear ball bearing 92-858064K01
Lubricant
5. Apply High‑Performance Gear Lubricant onto the outside diameter of the propeller shaft needle bearing and place the
propeller shaft needle bearing with the numbers facing aft, into the bearing carrier.
6. Press the bearing into the bearing carrier with the needle bearing driver tool until the tool is seated on the bearing carrier.
a - Needle bearing driver tool
48403

87 Outside diameter of the propeller shaft needle bearing 92-858064K01
Lubricant
Needle Bearing Driver 91‑15755T

Right-Hand Rotation
7. Install the first seal onto the long shoulder side of the oil seal driver. Verify the seal lip faces away from the mandrel
shoulder. Press the seal into the bearing carrier until the oil seal driver contacts the bearing carrier.
a - Oil seal
b - Oil seal driver
b
48361
Oil Seal Driver 91‑31108T

8. Apply Loctite 271 Threadlocker to the outside diameter of the second (outer) propeller shaft oil seal.
9. Install the second seal onto the short shoulder side of the oil seal driver. Verify the seal lip faces toward the oil seal driver
shoulder. Press the seal into the bearing carrier until the oil seal driver contacts the bearing carrier.
b a - Oil seal
b - Oil seal driver
48398

10. Remove excess Loctite 271 Threadlocker from the seal area.
11. Apply High‑Performance Gear Lubricant onto the outside diameter of the reverse gear ball bearing.

87 Outside diameter of the reverse gear ball bearing 92-858064K01
Lubricant
12. Place the bearing carrier over the thrust washer and the reverse gear assembly.
NOTE: Warming the bearing carrier with a torch lamp where the reverse gear assembly resides will aid in the installation of
the reverse gear assembly.

Right-Hand Rotation
13. Use a suitable mandrel to press the bearing carrier onto the bearing.
a - Mandrel
b - Bearing seated
a c - Thrust washer
c 56248
Torch Lamp Obtain Locally

14. Install an O‑ring between the bearing carrier and thrust washer.
15. Apply 2‑4‑C with PTFE to the oil seal lips and O‑ring.
16. Install the spacer into the reverse gear propeller shaft bore.
95
c
e
95
a b 61976
a- O‑ring
b- Thrust washer
c- Reverse gear
d- Propeller shaft seals (hidden)
e- Spacer

95 2-4-C with PTFE Oil seal lips and O-ring 92-802859A 1

Right-Hand Rotation
17. Install the bearing carrier onto the propeller shaft assembly. Apply 2‑4‑C with PTFE onto the bearing carrier gear housing
contact surfaces.
a
a - Bearing carrier
b - Propeller shaft assembly
95
95
62119

95 2-4-C with PTFE Bearing carrier gear housing contact surfaces 92-802859A 1
Forward Gear Assembly

1. Apply High‑Performance Gear Lubricant into the center bore of the forward gear.
2. Install the numbered side of the forward gear needle bearing onto the short shoulder side of the forward gear bearing tool.
NOTE: The bearing carrier needle bearing contacts the propeller shaft in front of the oil seal area. The forward gear
bearing contacts the propeller shaft in front of the clutch splines.
3. Press the bearing into the forward gear until the mandrel is against the gear.
a - Mandrel
b - Bearing
c - Forward gear
a
b
c
48568

87 Center bore of the forward gear 92-858064K01
Lubricant
4. Place the forward gear on a press with the gear teeth facing down.
5. Apply High‑Performance Gear Lubricant to the inside diameter of the forward gear tapered bearing and position the
forward gear tapered bearing over the gear.

Right-Hand Rotation
6. Use a suitable mandrel to press the bearing onto the forward gear until seated. Press only on the inner race of the bearing.
a a - Mandrel
b - Wood block
35614

87 Inside diameter of the forward gear tapered bearing 92-858064K01
Lubricant
7. Install the retaining ring into the groove of the forward gear, if equipped. Verify the retaining ring is seated in the groove.
a - Retaining ring
a
39701
Forward Gear Bearing Race Assembly

1. Place the shims retained from disassembly into the housing. If the shims were lost, or new components are used for
reassembly, start with a 0.762 mm (0.030 in.) shim.
2. Apply 2‑4‑C with PTFE to the outside diameter of the forward gear bearing race.

95 2-4-C with PTFE Outside diameter of forward gear bearing race 92-802859A 1
3. Install the forward gear bearing race into the gear housing.
4. Install the bearing cup driver and pilot ring onto the bearing cup/adapter installation tool.
5. Insert the installation tool into the gear housing. Verify the pilot ring is seated on the gearcase ledge.
6. Thread the retainer installer tool portion of the installation tool into the gearcase bearing carrier retainer and thread the
driver screw into the retainer installer tool.

Right-Hand Rotation
7. Secure the retainer installer tool and thread the driver screw in until the forward gear bearing race is seated in the gear
housing.
c d a- Driver screw
a b b- Retainer installer tool
c- Installation tool
d- Pilot ring
e- Bearing cup driver
f- Bearing race
g- Shims
e g
f
49534

Pilot Ring 91‑8M0074763
Driveshaft Assembly
1. Lubricate the inside diameter of a new driveshaft tapered bearing with High‑Performance Gear Lubricant.
2. Thread a used pinion nut onto the driveshaft and leave approximately 2 mm (0.079 in.) of nut threads exposed. The
driveshaft threads must not extend beyond the nut or thread damage may result.
3. Install the lower bearing onto the driveshaft with the small diameter of the bearing toward the pinion nut end of the
driveshaft.
4. Use the driveshaft bearing installation tool to press on the inner bearing race only until the bearing is seated on the
driveshaft.
a- Used pinion nut

a b- Driveshaft
c- Bearing
d- Driveshaft bearing installation tool
b e- Flat washer (obtain locally)
e
48776

87 Inside diameter of driveshaft tapered bearing 92-858064K01
Lubricant

5. Lubricate the inside diameter of a new upper driveshaft tapered bearing with High‑Performance Gear Lubricant.
6. Install the upper bearing onto the driveshaft with the large outside diameter of the bearing facing the pinion gear end of the
driveshaft.

Right-Hand Rotation
7. Press the upper bearing onto the driveshaft with the driveshaft bearing installation tool.
a- Pinion nut
b- Driveshaft
a c- Lower driveshaft tapered bearing
d- Upper driveshaft tapered bearing
e- Driveshaft bearing installation tool
b f- Flat washer (obtain locally)
c
d e
f
48778

87 Inside diameter of upper driveshaft tapered bearing 92-858064K01
Lubricant

8. Install the shims and lower driveshaft bearing cup into the gear housing.
9. Install the forward gear into the gear housing.
10. Position the pinion gear into the gear housing with the teeth of the pinion gear meshed with the forward gear.
11. Insert the driveshaft while holding the pinion gear. Rotate the driveshaft to align and engage the driveshaft splines with the
pinion gear splines.
IMPORTANT: Do not apply Loctite 271 Threadlocker to the threads on the driveshaft until after the gear backlash has been
checked.
NOTE: After the shimming process is completed, a new pinion nut must be installed. Refer to Forward Gear Backlash for
final installation information.
12. Install the flat washer and pinion nut onto the driveshaft with the flat side of the nut facing away from the pinion gear.
Hand‑tighten the pinion nut.
13. Place the upper driveshaft shims retained from the disassembly into the gear housing.
IMPORTANT: If the shims were lost or damaged, start with:
• 0.508 mm (0.020 in.) shim for the lower bearing
• 0.711 mm (0.028 in.) shim for the upper bearing
a a- Driveshaft
b- Pinion gear
g c- Washer
d- Pinion nut
f
e- Forward gear
f- Lower bearing shim
g- Upper bearing shim
e
b
c
d 56244
14. Lubricate the bearing retainer with 2‑4‑C with PTFE.

Right-Hand Rotation

95 2-4-C with PTFE Bearing retainer 92-802859A 1
15. Install the upper driveshaft bearing race and secure the bearing with the bearing retainer.
16. Tighten the bearing retainer with the driveshaft bearing retainer wrench to the specified torque.
a- Driveshaft bearing retainer wrench

b- Bearing retainer
c- Upper bearing race
a d- Upper bearing shim
e- Lower bearing race
b
c
d
e
f 49267

Bearing retainer 135.5 – 100

18. Use a socket and breaker bar to hold the pinion nut. Protect the area where the breaker bar will contact the gear housing
and tighten the pinion nut to the specified torque.
c a- Driveshaft holding tool

b- Torque wrench
c- Socket (7/8 in.)
b d- Breaker bar
a
a
d 48797

Pinion nut 101.7 – 75
19. Remove the pinion nut holding tool and the driveshaft holding tool.
20. Check the driveshaft rolling torque. Units correctly assembled to this point should be within the specified torque range. If
the driveshaft rolling torque is not within specification, the shim under the lower tapered roller bearing cup will need to be
changed and the driveshaft rolling torque rechecked. If the driveshaft rolling torque is too high, remove shims under the
lower bearing cup. If the driveshaft rolling torque is too low, add shims from under the lower bearing cup.

Right-Hand Rotation

Driveshaft rolling torque 0.45–1.13 4–10 –
Pinion Gear Depth

IMPORTANT: The forward gear assembly pilots the end of the pinion gauge and must be installed in the gear housing when
checking pinion gear depth. An inaccurate measurement will be obtained without the forward gear assembly installed.
IMPORTANT: Do not install the propeller shaft until after the pinion gear depth and forward gear backlash are within
specifications.
IMPORTANT: The preload tool is not required to check pinion gear depth when the gear housing is assembled with new
bearings.
The preload tool must be used to check pinion gear depth when the gear housing is assembled with used bearings.
NOTE: Read the entire procedure before attempting any change in shim thickness.
1. Ensure the gear housing is clear of debris in the bearing carrier area.
2. Position the gear housing with the driveshaft in a vertical position. Install the bearing preload tool with the correct sleeve
over the driveshaft in the sequence shown. Ensure the holes in the sleeve are in alignment with the set screws. Tighten the
set screws securely.
d a- Coupler
b- Threaded rod
c- Sleeve ‑ 22 mm (7/8 in.)
c e d- Sleeve ‑ 19 mm (3/4 in.)
e- Split sleeve ‑ 16 mm (5/8 in.)
f- Set screw (2)
f g- Bolt
g h- Spring
m i- Thrust washer
h j- Thrust bearing
b k- Adapter
i l- Plate
j m- Nut
a k
l
13288

3. Measure the distance between the top of the nut and the bottom of the bolt head.
4. Increase this distance by 25.4 mm (1 in.).
5. Rotate the driveshaft 5–10 revolutions to seat the driveshaft tapered roller bearing.
a
a - Bolt head
b - Nut
c - Measure distance, then increase by 25.4 mm (1 in.)
7275
6. Assemble the pinion gear locating tool, as shown.
a. Install the gauging block with the numbers toward the arbor handle.

Right-Hand Rotation
b. Position the split collar and gauging block against the pinion gauge adapter tool. Tighten the split collar retaining
screw.
c. Place the adapter tool on the arbor handle with side A toward the forward gear.
d a- Arbor handle
2
3
1
b- Screw (2)
c 8 4 e c- Gauging block
7 5
d- Split collar retaining screw
a 6
e- Split collar
b f
f- Pinion gauge adapter tool
• Side A toward the forward gear
b 56331

NOTE: The pinion gear locating tool 91‑12349A05 may be used to determine pinion depth if a pinion gauge adapter tool is
installed on the end of the arbor allowing it to properly match with the forward gear bearing diameter. The part number for
the pinion gear location tool upgrade kit is 91‑8M0089165. This kit includes a pinion gauge adapter tool and a #4 and #5
locating disc.
7. Insert the pinion gear locating tool into the forward gear assembly. Position the correct gauging block flat number under the
pinion gear, as shown.
a - Gauging block
a
7279
Model Gear Ratio (Pinion Gear Teeth/Reverse Gear Teeth) Use Flat Number Locating Disc Number
150 EFI 1.92:1 (13/25) 4 4
8. Install the locating disc against the bearing carrier shoulder in the gear housing.
9. Position the access hole, as shown.
a - Locating disc #4
a b - Access hole
b
7282

Right-Hand Rotation

10. Determine the pinion gear depth by inserting a feeler gauge through the access hole in the locating disc.
11. The correct clearance between the gauging block and the pinion gear is 0.64 mm (0.025 in.).
NOTE: Measure the pinion clearance at three locations 120° apart. Add the measurements and divide by three. This is the
average clearance of the pinion gear.
12. If the clearance is more than 0.64 mm (0.025 in.), remove shims under the upper driveshaft bearing race. If the clearance
is less than 0.64 mm (0.025 in.), add shims under the upper driveshaft bearing race.
NOTE: Changing the shims under the upper driveshaft bearing race will affect the driveshaft rolling torque. Check the
rolling torque after making any changes to the shims.
13. Check the pinion gear depth after making a change to the pinion gear shimming.
d a- Feeler gauge
c a b- Gauging block
c- Pinion gear
d- Pinion bearing race
7283
14. If the clearance is correct, leave the bearing preload tool on the driveshaft and proceed to Forward Gear Backlash.
Forward Gear Backlash

2. Insert the propeller shaft and bearing carrier assembly into the gear housing and thread the bearing carrier retainer tightly
against the bearing carrier. It is not necessary to torque the bearing carrier retainer against the bearing carrier.
3. Install the puller jaws assembly onto the gear housing.
4. Tighten the puller bolt to the specified torque.
a d a- Propeller shaft
b
b- Bearing carrier
c- Bearing carrier retainer
d- Puller jaws assembly
e- Puller bolt
e
c
35631

Puller bolt 8.5 75.2 –
5. Install the threaded rod onto the gear housing.

Right-Hand Rotation
6. Install the backlash indicator rod and dial indicator as shown.
c
b a- Backlash indicator rod
b- Plunger extension
c- Dial indicator adapter
d- Dial indicator
e- Threaded rod
d
e
56195

7. Align the dial indicator with the appropriate line on the backlash indicator rod. Ensure the dial indicator is perpendicular to
the backlash indicator or an inaccurate reading will be obtained.
NOTE: Backlash indicator 91‑8M0053505 utilizing line number one may also be used for checking forward gear backlash.
Backlash Indicator Tool Mark

Ratio Indicator number
1.92:1 (13 teeth pinion gear) 1
8. Lightly rotate the driveshaft back‑and‑forth. No movement should be noticed at the propeller shaft.
9. The dial indicator registers the amount of backlash. Ensure the forward gear backlash is within the specifications.

0.457–0.610 mm
1.92:1 (13/25)
(0.018–0.024 in.)
10. If the backlash is less than the minimum specification, remove shims from in front of the forward gear bearing race. If the
backlash is more than the maximum specification, add shims in front of the forward gear bearing race.
NOTE: By adding or subtracting 0.025 mm (0.001 in.), the backlash will change approximately 0.025 mm (0.001 in.).
11. Remove the puller jaws assembly and the backlash indicator assembly.
12. Remove the bearing carrier and propeller shaft assembly.
13. After the shimming process is completed, and the proper pinion gear depth is attained, a new pinion nut must be installed.
Remove and discard the old pinion nut. Retain the flat washer for reuse.
14. Clean the new pinion nut threads with Loctite 7649 Primer N before applying Loctite 271 Threadlocker.

15. Place a small amount of Loctite 271 Threadlocker onto the threads of the new pinion nut.

7 Loctite 271 Threadlocker Threads of the pinion nut 92-809819

Right-Hand Rotation

b- Torque wrench
c- Socket (7/8 in.)
b d- Breaker bar
a
a
d 48797

20. Remove the preload tool.
Reverse Gear Backlash (Standard Rotation)

Reverse gear backlash is not adjustable. If reverse gear backlash is not within specification, the gearcase is not properly
assembled or the parts are excessively worn and must be replaced.
1. Shift the gearcase into reverse.
2. Install a 152.5 x 38.0 mm (6.0 x 1.5 in. inside diameter) PVC pipe over the propeller shaft and position the pipe against the
bearing carrier.
3. Secure the pipe against the bearing carrier with the propeller nut and tab washer. Tighten the propeller nut to the specified
torque.
a - PVC pipe
b - Propeller nut
c - Tab washer
a
b
48513

Propeller nut 5.5 48.7 –
4. Install the coupler and threaded rod onto the gear housing stud.

Right-Hand Rotation
5. Install the backlash indicator rod and dial indicator as shown.
c
d- Dial indicator
e- Threaded rod
d
e
56195

6. Align the dial indicator with the appropriate line on the backlash indicator tool. Ensure the dial indicator is perpendicular to
the indicator tool or an inaccurate reading will be obtained.

7. Lightly rotate the driveshaft back‑and‑forth. No movement should be noticed at the propeller shaft.
8. The dial indicator registers the amount of backlash. Ensure that the reverse gear backlash is within the specifications.
Reverse Gear Backlash

0.305–0.838 mm
1.92: (13/25) standard rotation
(0.012–0.033 in.)
Propeller Shaft Bearing Preload

NOTE: All gear housing components must be installed and correctly shimmed before checking propeller shaft bearing preload.
The propeller shaft tapered roller bearing must be properly seated in the race during installation. The driveshaft retainer should
be torqued to specification.

Driveshaft retainer 135.5 – 100
1. Remove the bearing carrier.

2. Slide the preload spacer off of propeller shaft.
3. Install the (retained) propeller shaft preload shims onto the propeller shaft. If any shims were lost, start with 0.9 mm
(0.035 in.) shim thickness.
4. Install the preload spacer onto the propeller shaft.
5. Install the bearing carrier, aligning the rear propeller shaft bearing with the propeller shaft. It may be necessary to turn the
driveshaft to align the teeth of the pinion with the reverse gear.

Right-Hand Rotation
6. Insert the small rectangular tab of the tab washer into its corresponding slot in the gearcase at the 12 o'clock position
above the bearing carrier while aligning the U‑shaped tab of the tab washer with its corresponding slot below the lubricant
fill screw in the bearing carrier.
b a - Tab washer
b - Rectangular tab
c - U‑shaped tab
a
c 29392
7. With the gear housing in neutral, torque the bearing carrier retainer nut to initial specification.
8. Rotate the propeller shaft several times to seat the propeller shaft tapered roller bearings in their races.
9. Torque the bearing carrier retainer nut to final specification.

First 135.5 – 100
Bearing carrier retainer nut
Final 285 – 210
10. Install propeller shaft adapter and using a torque wrench, rotate propeller shaft in the direction of normal rotation with a
slow steady motion.
11. Verify rolling torque is within specification for new or used bearings.

Bearing rolling torque (new bearings) 1.1–1.8 10–16 –
Bearing rolling torque (used bearings) 0.45–1.1 4–10 –
NOTE: Preload will change approximately 0.056 Nm (1/2 lb‑in.) of rolling torque per 0.025 mm (0.001 in.) of shim change.
12. If rolling torque is too high, remove shims from propeller shaft ahead of tapered bearing/spacer in bearing carrier. If torque
is too low, add shims.
a - Torque wrench
b b - Propeller shaft adapter
2989
NOTE: If shims are changed, torque bearing carrier to initial specification. Rotate propeller shaft several times to seat
propeller shaft tapered bearing. Tighten the retainer nut to final specification. Use torque wrench to check rolling torque.
Repeat this procedure each time shims are changed.

Right-Hand Rotation

First 135.5 – 100
Bearing carrier
Final 285 – 210

1. Verify that the shift cam is installed in the neutral position and carefully insert the propeller shaft and bearing carrier
assembly into the forward gear inside the gear housing.
2. Apply Loctite 380 Black Max to the outside diameter of the shift shaft seal and install the seal into the shift shaft bushing
with the seal lip facing up toward the powerhead.
3. Install the O‑ring onto the shift shaft bushing and lubricate the O‑ring and seal lip with 2‑4‑C with PTFE.
95 a - Shift shaft seal

b - Bushing
c - O‑ring
a
134
b
c
95
48440

95 2-4-C with PTFE Shift shaft bushing O-ring and seal lip 92-802859A 1
4. Install the shift shaft bushing onto the E‑ring end of the shift shaft.
5. Insert the shift shaft into the gear housing and into the shift cam. It may be necessary to rotate the shift shaft slightly for the
shift shaft splines to align with the shift cam.
a
a- Seal
b c- O‑ring
d- E‑ring
c e- Shift shaft
d f- Shift shaft access hole
48449
6. Install the rubber washer over the shift shaft onto the bushing.

Right-Hand Rotation
7. Secure the shift shaft bushing into the gear housing with a retaining ring.
a- Shift shaft
a
c- Rubber washer
b d- Retaining ring
d
c
55954
8. Install the keyed tab washer.

a. Position index tab B into the gear housing.
b. Position index tab C into the bearing carrier.
a- Keyed tab washer

b a
b- Index tab B
c- Index tab C
d- Locking tab
c
d
d
56250

Right-Hand Rotation
9. Lubricate the threads of the retainer nut with 2‑4‑C with PTFE and install the retainer nut. Tighten the retainer nut to the
specified torque with the bearing carrier retainer nut wrench.
a- O‑ring
b- Retainer nut
c- Bearing carrier retainer nut wrench
d- Torque wrench
a b c d
95
48512

95 2-4-C with PTFE Threads of the retainer nut 92-802859A 1

Retainer nut 285 – 210.2

10. Bend the tab washer into the retainer nut.
11. Bend the remaining tabs of the tab washer toward the front of the gear housing.
NOTE: Replace the propeller bore sleeve if the sleeve is excessively worn or the retention tabs are broken.
12. After all backlash measurements are correct, ensure the propeller bore sleeve is installed on the bearing carrier retainer
nut. Failure to install the propeller bore sleeve will result in a loss of boat performance.
a - Propeller bore sleeve

a b - Gearcase oil fill screw
61978
13. Install the gearcase oil fill screw and tighten to the specified torque.

Gearcase oil fill screw 11.3 100 –

Right-Hand Rotation
Water Pump Assembly

IMPORTANT: If the oil seals within the oil seal carrier require replacement, the oil seal carrier must be replaced as an
assembly.
NOTE: The filler block is a press fit. No adhesive is required.
1. Inspect the filler block for damage. Replace the filler block as required.
2. Apply 2‑4‑C with PTFE to the seal lips and the oil seal carrier O‑ring.
a a - Oil seal carrier (oil seals are inside of the carrier)

b - O‑ring
c - Filler block
b
c
48519

95 2-4-C with PTFE Driveshaft oil seal carrier O-ring and seal lips 92-802859A 1
3. Install the oil seal carrier over the driveshaft and seat the carrier into the gearcase housing.
4. Secure the oil seal carrier assembly with a retaining ring.

b - Retaining ring
48281
NOTE: The faceplate may be reused if there are no grooves other than the impeller sealing ring groove.
5. Install the faceplate over the driveshaft and onto the gear housing.
The new three‑piece design can be used in place of the single‑piece overmolded faceplate.

Right-Hand Rotation
NOTE: The metal gasket may be reused if the black surface is not scratched or damaged. The faceplate may be reused if
there are no other grooves other than the impeller sealing ring groove. The fiber gasket may be reused if there is no
damage to the gray neoprene strip or the fiber gasket itself.
a
b - Faceplate
c - Metal gasket
48269
6. Apply 2‑4‑C with PTFE to the drive key and install the drive key and impeller.
IMPORTANT: If the old impeller is being reused, do not install the impeller in reverse rotation to its original set. Premature
a a - Impeller
b - Drive key
48268
7. If the old water pump cover is being reused, inspect the interior surface of the cover for grooves in excess of 0.762 mm
(0.030 in.). The impeller sealing groove is normal. Replace the cover as required.
8. Apply a light coat of 2‑4‑C with PTFE to the inside of the water pump cover. Install the water pump cover over the
driveshaft and while turning the driveshaft in a clockwise direction, press the water pump cover over the water pump
impeller.

Right-Hand Rotation
9. Secure the water pump cover with four screws. Tighten the screws to the specified torque, in the sequence shown.
4 3
2 1
61965
10. Install the water tube coupler onto the water pump cover.
11. Install the V‑ring face seal over the driveshaft. Use the V‑ring installation tool, supplied with the water pump kit, to seat the
V‑ring face seal against the water pump cover at the proper height.

c- Water pump cover
d
55949

95 2-4-C with PTFE Inside of water pump cover 92-802859A 1

Water pump cover screw (M6 x 20) (4) 6.8 60.2 –
Gear Housing Pressure Test

NOTE: The gear housing should be pressure tested for leaks after assembly and before the gear lubricant is added. The gear
housing should hold 103.4 kPa (15 psi) for 15 minutes.

Right-Hand Rotation
1. Remove the vent plug and install a pressure test gauge.
48537
2. Pressurize the housing to 103.4 kPa (15 psi) and observe the gauge for 15 minutes.
3. Rotate the driveshaft, propeller shaft, and shift shaft while the housing is pressurized to check for leaks.
4. If a pressure drop is noted, immerse the housing in water.
5. Pressurize the gear housing to 103.4 kPa (15 psi) and check for air bubbles.
6. Replace any leaking seals. Retest the housing after seal replacement.
Gearcase Test Pressure


7. Remove the tester from the housing and install the vent plug and sealing washer.
Gear Housing Installation

1. Tilt the engine to the full up position and engage the tilt lock lever.
2. Inspect the driveshaft housing to ensure the water tube, mounting studs, and mating surfaces are clean.
55958
NOTE: For L models with a 5 in. spacer, clean both mating surfaces of the spacer before installation.
NOTE: When installing the spacer it is recommended that masking tape be used to hold the spacer in place
3. Lubricate the driveshaft splines with Extreme Grease.
NOTICE
Installing the gear housing to the powerhead without adequately cleaning the top of the driveshaft can result in severe
product damage. Any lubricant trapped in the space between the driveshaft and the crankshaft prevent the two from properly
engaging. Always clean the top of the driveshaft before installing the gear housing.
4. Lubricate the shift shaft splines with Extreme Grease.
5. Insert the trim tab/anodic plate screw into the gear housing.

Right-Hand Rotation
6. Shift the gear housing into forward gear and place the shift block into the forward gear position.
a - Reverse gear position

a
c b - Neutral position
c - Shift block in the forward gear position
48526

7. Position the gear housing so the driveshaft is protruding into the driveshaft housing.
8. Move the gear housing up into the driveshaft housing while aligning the upper shift shaft with the lower shift shaft, the
water tube with the water tube coupler, and the driveshaft splines with the crankshaft splines.
NOTE: It may be necessary to rotate the flywheel or propeller shaft to align the driveshaft splines with the crankshaft
splines.
9. Place flat washers onto the studs located on either side of the driveshaft housing.
10. Engage a locknut onto these studs finger‑tight.
48245

Right-Hand Rotation
11. Thread the screw inside the trim tab/anodic plate recess into the driveshaft housing. Do not tighten the screw at this time.
a - Screw (M12 x 35)
48236
12. Check the shift shaft spline engagement and correct if necessary.
13. Alternately tighten the locknuts until the gearcase contacts the driveshaft housing.
14. Check the shift operation before installing the remaining washers, locknuts, and screw.
a. Move the shift block into forward gear position while turning the propeller shaft.
b. Rotate the flywheel clockwise: the propeller shaft should rotate clockwise.
c. Move the shift block into neutral position.
d. The propeller shaft should rotate freely in either direction.
e. Move the shift block into reverse gear position.
f. Rotate the flywheel clockwise and the propeller shaft should rotate counterclockwise.
NOTE: If the shifting operation is not as described, the gear housing must be removed and the cause corrected.
15. Tighten all the locknuts and the screw to the specified torque.
16. Install the anode and secure with the anode screw.
17. Tighten the anode screw to the specified torque and install the rubber cover into the anode screw hole opening.
a - Rubber cover
48235

Locknuts (M12 x 1.75) (4) 60 – 44.2
Screw (M12 x 35) 75 – 55.3
Anode screw (0.437‑14 x 1.75) 54 – 39.8

Right-Hand Rotation
Gear Lubricant Filling Instructions


1. Inspect the fill and vent sealing washers for cuts or abrasions. Replace the washers if necessary.
IMPORTANT: Never add lubricant to the gear housing without first removing the vent screw. Fill the gear housing only
when the housing is in a vertical position.
2. Slowly fill the gear housing through the fill hole with High‑Performance Gear Lubricant until lubricant flows out of the vent
hole and no air bubbles are visible.
3. Install the vent screw into the vent hole.
IMPORTANT: Do not lose more than 30 cc (1 fl oz) of gear lubricant while installing the fill screw.
4. Remove the grease tube (or hose) from the fill hole and quickly install the fill screw into the fill hole. Tighten the fill and vent
screws to the specified torque.
a - Fill screw
b - Vent screw
a
48252

Lubricant

Fill and vent screws 11.3 100 –



Right-Hand Rotation
IMPORTANT: Never add lubricant to the gear housing without first removing the vent plug.

62154

Lubricant


Left-Hand Rotation S/N 2B172248 and Below
Gear Housing
Section 6B - Left-Hand Rotation S/N 2B172248 and Below
Table of Contents
Left‑Hand Gear Housing Specifications, S/N 2B172248 Pinion Gear and Driveshaft Removal...............................6B-30
and Below.......................................................................6B-2 Driveshaft Cleaning and Inspection.......................... 6B-33
Gear Housing (Driveshaft)............................................... 6B-10 Reverse (Front) Gear Removal and Disassembly........... 6B-33
Gear Housing, Propeller Shaft, Counterrotation S/N Cleaning and Inspection........................................... 6B-34
2B172248 and Below................................................... 6B-12 Gear Housing Inspection................................................. 6B-35
General Service Recommendations................................ 6B-14 Pinion Bearing Installation............................................... 6B-36
Bearings....................................................................6B-14 Forward Gear Bearing Adapter and Bearing Carrier
Shims........................................................................6B-14 Assembly......................................................................6B-36
Seals.........................................................................6B-14 Forward Gear Bearing Adapter Assembly................ 6B-36
Gearcase Removal ......................................................... 6B-15 Bearing Carrier Assembly.........................................6B-37
Gearcase Service Inspection........................................... 6B-16 Reverse (Front) Gear and Bearing Adapter Assembly ... 6B-38
Draining and Inspecting Gear Housing Lubricant..... 6B-16 Reverse (Front) Gear Assembly............................... 6B-38
Propeller Shaft Inspection.........................................6B-17 Bearing Adapter Assembly....................................... 6B-39
6
Water Pump Removal and Disassembly......................... 6B-17 Reverse (Front) Gear Bearing Adapter and Gear
Cleaning and Inspection........................................... 6B-19 Installation.................................................................... 6B-39
Oil Seal Carrier Assembly................................................6B-20 Driveshaft Assembly........................................................ 6B-41
Removal....................................................................6B-20
Disassembly............................................................. 6B-21
Pinion Gear Depth........................................................... 6B-44
Propeller Shaft Assembly.................................................6B-47
B
Bearing Carrier and Propeller Shaft Removal .................6B-21 Shift Shaft Installation...................................................... 6B-55
Shift Shaft Inspection................................................6B-24 Forward Gear Backlash................................................... 6B-57
Bearing Carrier Disassembly........................................... 6B-24 Propeller Shaft Bearing Preload...................................... 6B-58
Propeller Shaft Inspection and Disassembly................... 6B-25 Water Pump Assembly.................................................... 6B-60
Propeller Shaft Inspection.........................................6B-25 Gear Housing Pressure Test........................................... 6B-62
Propeller Shaft Disassembly, Early Design.............. 6B-26 Gear Housing Installation—Left‑Hand Rotation...............6B-63
Propeller Shaft Disassembly, Later Design.............. 6B-28 Gear Lubricant Filling Instructions................................... 6B-66
Forward Gear and Bearing Adapter Disassembly .......... 6B-29

Left‑Hand Gear Housing Specifications, S/N 2B172248 and Below

Left‑Hand Gear Housing Specifications S/N 2B172248 and below
Water pressure
At WOT 80–300 kPa (11.6–43.5 psi)

Bearings
Outside diameter of the forward gear bearing
Outside diameter of propeller shaft needle bearing
Inside diameter of the bearing adapter and the outside diameter
High-Performance Gear of the bearing
87 92-858064K01
Lubricant Inside diameter of driveshaft tapered bearing
Forward gear bearing rollers and outside diameter of the forward
gear bearing race
Gear housing
Pinion bearing bore
Oil seal lips
Outside diameter of bearing adapter
Thrust washer and thrust bearing
Bearing retainer
Forward propeller shaft thrust bearing and thrust washer
Forward gear thrust washer
95 2-4-C with PTFE Forward gear thrust bearing 92-802859A 1
Pocket on cam follower
Bearing carrier O-ring
Aft thrust bearing
Aft thrust washer
Bearing carrier gear housing contact surfaces

Special Tools

location, and TDC.
9479

2999
29496
46139
9514

48577

48578

49768

9520
28677
Removes bearings from gears and the driveshaft.
8505
49079
29490


11‑ 24156 Hex Nut
12‑ 34961 Washer
91‑ 29310 Plate
6761
Needle Bearing Driver 91‑ 15755T
Installs needle bearings into bearing carriers
10787
Oil Seal Driver 91‑ 31108T
Installs bearing carrier oil seals
8883
Install reverse gear bearing in left‑hand rotation gearcase
48575

Mandrel 8M0039014
Install reverse gear bearing adapter
49522
49261
Maintains the alignment of the driver tool
49263
Installer Pilot 91‑8M0048035
49265
47416
measurements.
8756


B A
56235
60578
Allows pinion locating gauge to adapt to various front gear bearings. Tool is
included with pinion gear locating tool P/N 91‑8M0089163 and pinion gear
locating tool upgrade kit P/N 91‑8M0089165.
56254
49549
Backlash Indicator Rod 91‑ 8M0053505

9450
inch prop
10805
47536

29497

Notes:


42
11
42
12
14 10
13
31 15
16
17
18
19
34
40
20
21
6
22
35 32
37 23
36 41
38 33
43
39 24
8 7 5
25
26
4
7 27
9 28
29
44 30
23
1
45 3
48386


Torque
1 1 Gearcase
2 1 Plug
3 2 Seal
7 2 Anode
8 1 Screw (M6 x 40) 6.8 60.2 –
10 1 Filler block
12 4 Screw (M6 x 20) 6.8 60.2 –
15 1 Drive key
16 1 Impeller
17 1 Gasket
18 1 Faceplate
19 1 Gasket
20 1 Retaining ring
22 2 Oil seal
23 1 O‑ring (2.175 x 0.103)
24 1 Retainer 135.5 – 100
27 1 Shim
30 1 Shim
31 1 Driveshaft
32 1 Pinion gear
33 1 Nut (0.625‑18) 101.7 – 75
34 1 Shift shaft
35 1 Retaining ring
36 1 Oil seal
37 1 Washer
39 1 O‑ring
40 1 E‑ring
41 1 Washer
42 2 O‑ring (0.796 x 0.139)
43 1 Screw (0.437‑14 x 1.750) 54 – 39.8
44 1 Anode
45 1 Vent screw 11.3 100 –

Gear Housing, Propeller Shaft, Counterrotation S/N 2B172248 and Below
19 22 23
4
5
21
20
17 18 3
12 15 16
10 13
14
9 11
8
5 6 7
4 12
2 3
33
32
31
30
25 29
28
22
23
24 27 26
48388

Gear Housing, Propeller Shaft, Counterrotation S/N 2B172248 and Below

Torque
1 1 Gear housing
2 1 Reverse gear adapter
3 2 Needle roller bearing assembly
4 2 Thrust washer
5 2 Thrust bearing
6 1 Retaining ring
7 1 Needle bearing
8 1 Reverse gear (25 teeth)
9 1 Cam follower
10 1 Shift cam
12 2 Ball bearing (0.250 in. diameter) NLA, no longer required
13 1 Compression spring (0.305 in. O.D.) NLA, no longer required
14 1 Ball bearing (0.3125 in. diameter) NLA, no longer required
17 1 Cross pin
18 1 Forward gear (25 teeth)
19 1 Forward gear bearing adapter
20 1 Spacer shim
21 1 O‑ring (3.975 x 0.210)
22 2 Thrust washer
23 2 Thrust bearing
26 1 Seal
27 1 Fill screw 11.3 100 –
28 1 Needle bearing
29 1 Oil seal
30 1 Oil seal
31 1 Tab washer
32 1 Retainer 285 – 210.2


Bearings
be replaced.

87 Bearings 92-858064K01
Lubricant
Shims
Seals

95 2-4-C with PTFE 92-802859A 1

Gearcase Removal
! WARNING

b a- Tab washer
f
d- Rear thrust hub
e- Propeller shaft
f- Front thrust hub
d c e
48808
a - Rubber cover
48235

a - Screw
48236
48245


a - Fill screw
b - Vent screw
a
48252

b a - Propeller shaft
b - Dial indicator, checking for runout
61941
Propeller Shaft
Runout 0.152 mm (0.006 in.)




c- Water pump cover
d
55949

7. Remove the water pump faceplate.
a - Impeller
b - Drive key
c - Faceplate with molded gasket
a
c b
55950
Remove the water pump faceplate, and both gaskets, if equipped.
a
b - Faceplate
c - Metal gasket
48269


2. Inspect the faceplate for grooves or rough surfaces. Inspect the overmolded gasket material for damage.
a b c
55951
Single-piece overmolded gasket

a - Water pump impeller side of faceplate
b - Overmolded gasket material
c - Bottom side overmolded gasket material
NOTE: A damaged overmolded faceplate will be replaced by the new three‑piece faceplate and gaskets design. Inspect
the new three‑piece face plate and gaskets design as follows.
a. Inspect the stainless steel gasket coated surface for scratches or damage. If the coating is scratched or damaged,
replace the stainless steel gasket.

a
b - Coating
b
46007
b. Inspect the faceplate for grooves or rough surfaces. Replace the faceplate if damage is found.
c. Inspect the fiber gasket. Replace the fiber gasket if damage is found.
55952

b a - Impeller
55953

Removal

b - Retaining ring
48281


c - Protective pad
a
c
b
48284

b - O‑ring
48291
Disassembly

IMPORTANT: The gear housing must be in neutral before the propeller shaft can be removed.


c - Lock tabs
a
b
c
48306
35528

48311
7. Verify that the gear housing is in neutral. Remove the shift shaft rubber washer and retaining ring.

a- Shift shaft
a
c- Rubber washer
b d- Retaining ring
d
c
55954

a
48317

d
a
b
48555
a- Long jaws
b- Puller bolt
c- Thrust hub
d- Shift shaft bushing
e- Shift shaft

11. Remove the propeller shaft, cam follower, and shift cam by pulling the propeller shaft straight out of the gear housing. Do
not jerk the propeller shaft out of the gear housing. If the propeller shaft will not come out, proceed as follows:


1. Remove the thrust bearing and thrust washer from the bearing carrier.

2. If the thrust bearing, thrust washer, or thrust bearing surface on the propeller shaft show signs of rust, pitting, or bluing,
replace the components as required.
a a - Thrust bearing
b - Thrust washer
c - Bearing carrier
39926
3. Remove the propeller shaft oil seals from the bearing carrier with a pry bar or slide hammer.
a - Pry bar
a b - Seals
c - Bearing
b
39928
4. Press the propeller shaft needle bearing out of the bearing carrier with a suitable mandrel.
a
a - Driver rod
b - Mandrel
c - Bearing
39929

2. Inspect the area of the oil seals for grooves. Replace the propeller shaft if grooves are found.
overheating. Replace the shaft and corresponding needle bearing if any of the previous mentioned conditions are found.

• Position the propeller shaft roller bearing surfaces on balance wheels or V‑blocks. Use a dial indicator at the front
edge of the propeller splines. Rotate the propeller shaft. Dial indicator movement more than the specification requires
the propeller shaft to be replaced.
a - Dial indicator location

b - Needle bearing surface
b
b
61913
Propeller Shaft
Runout 0.152 mm (0.006 in.)
Propeller Shaft Disassembly, Early Design

c a - Shift cam
b b - Retaining spring
a c - Awl
48601
3. Push the cross pin out of the clutch and propeller shaft with the actuator assembly tool.
NOTE: If either end of the actuator assembly tool is lost, the long threaded pull pin can be ordered through part number
91‑8M0045645. The short pin stop end can be ordered through part number 91‑8M0045644.
a a - Cross pin
b - Clutch
b c - Actuator assembly tool
c 48602


4. Remove the clutch from the propeller shaft.
a - Forward gear clutch dog teeth

b - Reverse gear clutch dog teeth
b
a 48603
5. Inspect the clutch for damage. Damage to the clutch indicates one or more of the following:
a. Improper shift cable adjustment
b. Improper shift technique ‑ shifting too slow
c. Engine RPM too high while shifting
7. Disconnect the clutch actuator rod from the cam follower.
c d
a d
b e
49129
a- Compression spring
b- Ball bearing, 7.94 mm (0.3125 in.) diameter
c- Clutch actuator rod
d- Ball bearing, 6.4 mm (0.250 in.) diameter (2)
e- Cam follower
NOTE: The compression spring and ball bearings (items a, b, and d) were removed from production and should be
discarded during disassembly, and not reused.
8. Check the condition of the cam follower. If it shows wear, pitting, scoring, or rough surface, replace the cam follower and
shift cam.
9. Remove the forward (rear) gear, spacer, O‑ring, and bearing adapter assembly.

10. Remove the two thrust bearings and thrust washers from the propeller shaft.
c e
a- Thrust washers
b
b- Thrust bearings
c- Bearing adapter assembly
d- O‑ring
e- Spacer
f- Forward (rear) gear
f
a d 49152
Propeller Shaft Disassembly, Later Design

a c a - Awl
c - Shift cam
61924
3. Push the cross pin out of the clutch and propeller shaft with an appropriate tool.
a - Cross pin
b - Clutch
b
a
55740


a - Forward (rear) gear

assembly
b - Clutch
c - Clutch actuator rod
d - Cam follower
c
d
a b 55741
shift cam.
9. Remove the forward (rear) gear assembly.
a
a - Forward (rear) gear assembly
55742
Forward Gear and Bearing Adapter Disassembly

1. Remove the forward gear from the bearing adapter.
2. Inspect the clutch dog teeth on the forward gear for signs of wear. Replace the gear and clutch if necessary.
3. Inspect the forward gear clutch dog teeth for damage. Replace if necessary.
4. Inspect the forward gear hub for signs of pitting, rust, scoring, or discoloration.
5. Remove the thrust bearing and spacer. Inspect the thrust bearing for pitting, rust, or discoloration. Replace the bearing if
b a- Gear teeth
b- Clutch teeth
c- Hub
a d- Thrust bearing
e- Thrust washer
c f- Spacer
d
e
f 39772
6. Remove the thrust washer and O‑ring.

7. Remove the thrust bearing and thrust washer from the bearing adapter. Inspect the thrust bearing and washer for pitting,
rust, or signs of discoloration. Replace the components if any of these conditions are found.
b c
d
e
a
39773
a- O‑ring
b- Thrust washer
c- Thrust bearing
d- Thrust washer
e- Bearing adapter
8. Carefully inspect the forward gear bearing for pitting, rust, or signs of discoloration. Replace the bearing if any of these
conditions are found. Use a hammer and punch to remove the bearing from the bearing adapter. Be careful not to damage
the bearing adapter when removing the bearing.
a - Forward gear bearing

b - Bearing adapter
a
39776

48340


driveshaft.
the 18 rollers.
a - Wood block
b a
48341
9. Remove the pinion gear and reverse (front) gear assembly from the gear housing. Refer to Reverse Gear Removal and
Disassembly.
covers.

a - Upper bearings
a
56202


b - Pilot washer
c - Driver rod
48344



! WARNING
b a - Splines
a c a
56198
Reverse (Front) Gear Removal and Disassembly

1. Remove the reverse (front) gear from the gear housing.
39779
rust, or discoloration. Replace the components if any of these conditions are found.
a - Thrust bearing
a b - Thrust washer
c - Bearing adapter
c
39782

3. Use the two jaw puller, a threaded rod, washer, and guide plate to remove the reverse (front) gear bearing adapter.
a a- Threaded rod
c b- Nut
b c- Washer
d d- Guide plate
e- Two jaw puller head
e
39787


1. Clean the reverse (front) gear and bearing with a mild solvent. Dry with compressed air. Do not spin the bearing.
! WARNING
3. Inspect the clutch dogs on the reverse (front) gear for damage. Replace the reverse (front) gear if damage is found.
a - Gear teeth
b - Clutch dogs
39789
4. Inspect the needle bearings on the inside of the reverse (front) gear. Inspect the bearing surface on the propeller shaft. If
either the needle bearings, or the bearing surface of the propeller shaft are pitted, grooved, worn unevenly, discolored, or
has embedded particles, replace the propeller shaft and needle bearing in the reverse (front) gear.
NOTE: The needle bearing in the reverse (front) gear should not be removed unless damaged.
5. Remove the retaining ring securing the propeller shaft needle bearing.

6. Use a suitable mandrel to press the bearing out of the gear.
c e
a
b
d
48695
a- Propeller shaft
b- Reverse (front) gear
c- Retaining ring
d- Numbered side of bearing
e- Needle bearing
IMPORTANT: Press on the number/letter side of the needle bearing when installing the bearing into the reverse (front) gear.

a
49365

holes.

a- Puller rod
b- Puller plate
a c- Pilot washer
f e- Mandrel
b f- Hex nut
e
48970

Forward Gear Bearing Adapter and Bearing Carrier Assembly

Forward Gear Bearing Adapter Assembly
1. Lubricate the outside diameter of the forward gear bearing with High‑Performance Gear Lubricant.
2. With a suitable mandrel, press the numbered side of the bearing into the bearing adapter until the bearing is flush with the
adapter.
a
a - Mandrel
b - Bearing
b c - Bearing adapter
c 39930


87 Outside diameter of the forward gear bearing 92-858064K01
Lubricant
Bearing Carrier Assembly

1. Lubricate the outside diameter of the propeller shaft needle bearing with High‑Performance Gear Lubricant.
2. Press on the numbered side of the bearing into the bearing carrier until the mandrel contacts the bearing carrier.
a
a - Mandrel
b - Needle bearing
b
39931

87 Outside diameter of propeller shaft needle bearing 92-858064K01
Lubricant
Needle Bearing Driver 91‑ 15755T

3. Install the first propeller shaft seal into a clean and dry bearing carrier bore.
4. Install the first seal onto the long shoulder side of the oil seal driver mandrel. Verify the seal lip faces away from the
mandrel shoulder. Press the seal into the bearing carrier until the mandrel contacts the bearing carrier.
a a - Oil seal
b b - Mandrel
c - Bearing
39932
Oil Seal Driver 91‑ 31108T

5. Apply Loctite 271 Threadlocker to the outside diameter of the second propeller shaft oil seal.

6. Install the second seal onto the short shoulder side of the oil seal driver mandrel. Verify the seal lip faces toward the
mandrel shoulder. Press the seal into the bearing carrier until the mandrel driver contacts the bearing carrier.
a - Oil seal
a b - Mandrel
b
39933

7. Apply 2‑4‑C with PTFE to the oil seal lips.

95 2-4-C with PTFE Oil seal lips 92-802859A 1
Reverse (Front) Gear and Bearing Adapter Assembly

Reverse (Front) Gear Assembly
1. Lubricate the outside diameter of the propeller shaft needle bearing with High‑Performance Gear Lubricant.
2. Place the reverse (front) gear onto a press with the teeth facing down.
3. Install the propeller shaft needle bearing with the numbers facing up toward the mandrel.
4. With the mandrel inserted into the bearing, press on the numbered side of the bearing until the mandrel contacts the gear.
a - Mandrel
b - Bearing (numbers face up)
c - Reverse (front) gear
a
b
c
48576

87 Outside diameter of propeller shaft needle bearing 92-858064K01
Lubricant

Bearing Adapter Assembly

1. Lubricate the inside diameter of the bearing adapter and the outside diameter of the bearing with High‑Performance Gear
Lubricant.
2. Place the bearing with the numbers facing up on a press.
3. Press the bearing into the bearing adapter with a suitable mandrel until the mandrel contacts the bearing adapter.
a - Mandrel
b - Bearing adapter
a c - Bearing
39937

High-Performance Gear Inside diameter of the bearing adapter and the outside
87 92-858064K01
Lubricant diameter of the bearing
Reverse (Front) Gear Bearing Adapter and Gear Installation

1. Lubricate the outside diameter of the bearing adapter with 2‑4‑C with PTFE.
2. Position the bearing adapter into the gear housing bore.
a - Bearing adapter
49253

95 2-4-C with PTFE Outside diameter of bearing adapter 92-802859A 1

3. Install the reverse (front) gear bearing mandrel into the bearing adapter.
a - Mandrel
b - Bearing adapter
b
49535
Mandrel 8M0039014
4. Install the pilot ring onto the driver tool and install the tool assembly into the gear housing. Verify the pilot ring is seated on
the gearcase ledge.
5. Thread the adapter into the gearcase bearing carrier retainer threads and install the driver screw into the adapter.
6. Secure the adapter and thread the driver screw in until the bearing adapter is seated in the gear housing.
IMPORTANT: Do not overtighten the driver screw. Overtightening the driver screw will damage the bearing inside the
bearing adapter.
c d a- Driver screw
a b b- Adapter
c- Driver tool
d- Installer pilot
e- Mandrel
f- Bearing adapter
e
f
62167
IMPORTANT: Bearing cup/adapter installation tool 91‑18605A2 can be used to install the right‑hand forward gear bearing
race and the left‑hand reverse gear bearing adapter if retainer installer tool 91‑8M0048109 and installer pilot
91‑8M0048035 are used.

7. Remove the adapter, pilot ring, and driver tool from the gear housing.
8. Install the thrust washer onto the bearing adapter.

9. Lubricate the thrust bearing and thrust washer with 2‑4‑C with PTFE and install the bearing onto the thrust washer. The
2‑4‑C with PTFE will help keep the thrust washer and thrust bearing in position during assembly.
a - Thrust bearing
b - Thrust washer
a c - Bearing adapter
b c
39961

95 2-4-C with PTFE Thrust washer and thrust bearing 92-802859A 1
10. Install the reverse (front) gear onto the bearing adapter.
a - Reverse (front) gear

b - Thrust bearing and thrust washer
a
39962
Driveshaft Assembly
driveshaft.
driveshaft.
a- Used pinion nut

a b- Driveshaft
c- Bearing
e
48776


Lubricant

driveshaft.
a- Pinion nut
b- Driveshaft
c
d e
f
48778

Lubricant

9. Position the pinion gear into the gear housing with the teeth of the pinion gear meshed with the reverse (front) gear.
checked.
NOTE: After the shimming process is completed, a new pinion nut must be installed. Refer to Pinion Gear Depth for final
installation information.

a a- Driveshaft
b- Pinion gear
g c- Washer
d- Pinion nut
f
e- Reverse (front) gear
e
b
c
d 56244


b- Bearing retainer
b
c
d
e
f 49267




b- Torque wrench
c- Socket (7/8 in.)
b d- Breaker bar
a
a
d 48797

the driveshaft rolling torque is not within specification, the shim under the upper tapered roller bearing cup will need to be
upper bearing cup. If the driveshaft rolling torque is too low, add shims from under the upper bearing cup.

Pinion Gear Depth

IMPORTANT: The reverse (front) gear assembly pilots the end of the pinion gauge and must be installed in the gear housing
when checking pinion gear depth. An inaccurate measurement will be obtained without the reverse (front) gear assembly
installed.
IMPORTANT: Do not assemble the propeller shaft until after the pinion gear depth and reverse gear backlash are within
specifications.
bearings.

d a- Coupler
b- Threaded rod
f- Set screw (2)
f g- Bolt
g h- Spring
m i- Thrust washer
h j- Thrust bearing
b k- Adapter
i l- Plate
j m- Nut
a k
l
13288

a
a - Bolt head
b - Nut
7275
6. Assemble the pinion gear locating tool, as shown. Ensure that the pinion gauge adapter tool is secured in the groove of the
arbor.
a. Install the gauging block with the numbers pointed toward the arbor handle.
b. Establish a 0.063 inch gap between the gauging block/split collar assembly and the pinion gauge adapter tool. A
propeller shaft thrust washer can be used to establish the correct gap. Tighten the split collar retaining screw.
c. Place the adapter tool on the arbor handle with side A toward the front gear.
d a- Arbor handle
2
3
1
b- Screw (2)
7 5
a 6
g e- Split collar
b f
• Side A toward the front gear
g - 0.063 inch gap
b 61997


NOTE: Pinion gear locating tool 91‑12349A05 may be used to determine pinion depth if a pinion gauge adapter tool is
installed on the end of the arbor allowing it to properly match with the reverse gear bearing diameter. A 0.063 inch gap
must exist between the pinion gauge adapter tool and the gauging block/split collar assembly for the pinion gear locating
tool to provide accurate measurements. A propeller shaft thrust washer can be used to establish the correct gap. The part
number for the pinion gear location tool upgrade kit is 91‑8M0089165. This kit includes a pinion gauge adapter tool and a
#4 locating disc.
7. Insert the pinion gear locating tool into the reverse (front) gear assembly. Position the correct gauging block flat number
under the pinion gear, as shown.
a - Gauging block
a
7279
150 EFI 1.92:1 (13/25) 4 4
a b - Access hole
b
7282

is less than 0.64 mm (0.025 in.), add shims under the driveshaft bearing race.

13. Check the pinion gear depth after making any change to the pinion gear shimming.
d a- Feeler gauge
c- Pinion gear
7283
14. Remove the preload tool.



18. Install the flat washer and the new pinion nut onto the driveshaft with the flat side of the nut facing away from the pinion
gear. Hand‑tighten the pinion nut.

b- Torque wrench
c- Socket (7/8 in.)
b d- Breaker bar
a
a
d 48797


IMPORTANT: The propeller shaft with the forward gear bearing adapter and bearing carrier assembly must be assembled and
installed in the gear housing before the forward gear backlash can be checked.

NOTE: Applying 2‑4‑C with PTFE to the forward propeller shaft thrust bearing and thrust washer will assist in retaining the
bearing and washer in position during assembly.
1. Apply 2‑4‑C with PTFE to the forward propeller shaft thrust bearing and thrust washer. Install the thrust bearing and the
thrust washer onto the propeller shaft.
a - Thrust bearing
b - Thrust washer
b
48639

95 2-4-C with PTFE Forward propeller shaft thrust bearing and thrust washer 92-802859A 1
NOTE: If the bearing in the forward gear bearing adapter requires replacement, applying heat to the bearing adapter will
aid in the removal of the bearing. Use a punch to drive the bearing out of the adapter. Using a suitable mandrel, press the
new bearing with the numbers/letters facing up into the adapter until it seats. Lubricate the outside diameter of the bearing
race with High‑Performance Gear Lubricant before pressing the bearing into the adapter.
c
a
d
b
48640
a- Forward gear bearing adapter

b- Forward gear bearing
c- Drift punch access holes
d- Numbers/letters face up

2. Apply High‑Performance Gear Lubricant onto the forward gear bearing rollers and install the adapter onto the propeller
shaft.
a - Propeller shaft
a b - Forward gear bearing adapter
48641

High-Performance Gear Forward gear bearing rollers and outside diameter of the
87 92-858064K01
Lubricant forward gear bearing race
3. Apply 2‑4‑C with PTFE to the forward gear thrust washer and install the thrust washer onto the adapter. The 2‑4‑C with
PTFE will help retain the thrust washer during assembly.
a - Forward gear thrust washer
48642

95 2-4-C with PTFE Forward gear thrust washer 92-802859A 1

4. Apply 2‑4‑C with PTFE to the forward gear thrust bearing and install the bearing onto the adapter. The 2‑4‑C with PTFE
will help retain the thrust bearing during assembly.
a - Forward gear thrust bearing
48643

95 2-4-C with PTFE Forward gear thrust bearing 92-802859A 1
NOTE: If the original forward gear bearing adapter spacer was damaged or lost and the dimension was not recorded,
install a 5.48 mm (0.216 in.) spacer.
5. Install the forward gear bearing adapter spacer onto the bearing adapter.
a - Spacer
48644
6. Install the forward gear onto the bearing adapter.
a - Forward gear
48645

7. While aligning the cross pin hole in the clutch dog with the slot in the propeller shaft, install the clutch dog onto the
propeller shaft.
b a - Clutch dog
b - Slot in propeller shaft
c - Cross pin hole
48646
a b a - Cam follower
b - Actuator rod
61973
NOTE: The propeller shaft is equipped with one of two different styles of shift cams and cam followers. The installation
instructions are the same for either, but only the earlier style is shown in the steps below.
a
c a- Earlier style shift cam
b- Earlier style cam follower
c- Later style shift cam
b d
d- Later style cam follower
61972
9. Align the cross pin opening in the actuator rod with the cross pin hole in the clutch dog. Insert the clutch actuator rod
assembly into the end of the propeller shaft. Position the actuator rod far enough into the propeller shaft to align the hole in
the actuator with the cross pin hole in the clutch dog.
a - Cross pin hole

b - Propeller shaft
c - Cross pin opening in
actuator rod
d - Cam follower
c
b d
a
61974

10. Insert the cross pin into the clutch dog. The cross pin will be flush on either side of the clutch groove when properly
installed.
b a - Cross pin
b - Clutch groove
a
61975
a - Retaining spring
b b - Cross pin (hidden)
a
48651
a - Shift cam (letters face up)

95
a b - Cam follower
b
48652

95 2-4-C with PTFE Pocket on cam follower 92-802859A 1

13. Apply 2‑4‑C with PTFE to the bearing carrier O‑ring. Install the O‑ring onto the forward gear bearing carrier adapter.
b a - Bearing carrier adapter

a b - O‑ring
48657
95

95 2-4-C with PTFE Bearing carrier O-ring 92-802859A 1
14. Apply 2‑4‑C with PTFE to the aft thrust bearing. Install the aft thrust bearing onto the propeller shaft. The 2‑4‑C with PTFE
will help keep the thrust bearing in position during assembly.
a - Aft thrust bearing
a
48658

95 2-4-C with PTFE Aft thrust bearing 92-802859A 1

IMPORTANT: Prior to installing the bearing carrier onto the propeller shaft assembly, verify the notches and slots in the
forward gear bearing carrier adapter are aligned with their matching locations in the bearing carrier.
a b
d 48659
a- Bearing carrier
b- Forward gear bearing carrier adapter
c- Locating tab and slot (12 o'clock position on bearing carrier)
d- Oil drain slot (6 o'clock position on bearing carrier)
15. Apply 2‑4‑C with PTFE to the aft thrust washer and install the aft thrust washer into the bearing carrier.
b a - Bearing carrier
b - Aft thrust washer
48660

95 2-4-C with PTFE Aft thrust washer 92-802859A 1
NOTE: Installing a 15.2 x 3.8 cm (6.0 x 1.5 in.) long PVC pipe over the propeller shaft and securing it against the bearing
carrier with a propeller nut and washer will help hold the propeller shaft/bearing carrier assembly in alignment while
installing the assembly into the gear housing.

16. Install the bearing carrier onto the propeller shaft assembly. Apply 2‑4‑C with PTFE onto the bearing carrier gear housing
contact surfaces.
95
a 48661
a - Bearing carrier

95 2-4-C with PTFE Bearing carrier gear housing contact surfaces 92-802859A 1

1. Verify the clutch is in the neutral position and carefully install the propeller shaft and bearing carrier assembly into the
reverse gear located inside the gear housing.
NOTE: Do not allow the thrust bearing to become loose between the forward gear and the bearing carrier adapter. A loose
thrust bearing may become pinched between the forward gear and the bearing adapter. The bearing will be damaged
when the retainer nut is tightened.
2. Apply Loctite 380 Black Max to the outside diameter of the shift shaft seal and install the seal into the shift shaft bushing
with the seal lip facing up toward the powerhead.

b - Bushing
c - O‑ring
a
134
b
c
95
48440


a
a- Seal
b c- O‑ring
d- E‑ring
c e- Shift shaft
48449
a- Shift shaft
a
c- Rubber washer
b d- Retaining ring
d
c
55954

a- Keyed tab washer

b a
b- Index tab B
c- Index tab C
d- Locking tab
c
d
d
56250

a- O‑ring
b- Retainer nut
d- Torque wrench
a b c d
95
48512


Retainer nut 285 – 210

1. Install the dial indicator adapter to the gear housing. lnstall the backlash indicator rod and dial indicator as shown.
c
d- Dial indicator
e- Threaded rod
d
e
56195

Backlash Indicator Rod 91‑ 8M0053505


3. Rotate the shift shaft into the forward (rear) gear position.
4. Rotate the shift shaft into the neutral position.
5. While holding the shift shaft in the neutral position, rotate the driveshaft approximately 30° and then rotate the shift shaft
counterclockwise toward the forward gear position. Ideally, the shift shaft should not go into the forward gear position. The
clutch dogs should butt against the forward gear clutch dogs. Hold the shift shaft firmly in this position.
6. While firmly holding the clutch against the forward gear with the shift shaft, lightly rotate the driveshaft back‑and‑forth.

0.483–0.610 mm
1.92:1 (13/25)
(0.019–0.024 in.)
8. If the backlash is less than the minimum specification, install a thicker spacer shim in front of the bearing adapter. If the
backlash is more than the maximum specification, install a thinner spacer shim in front of the bearing adapter.
9. After all backlash measurements are correct, bend the locking tab washer tab into the retainer nut. Bend the remaining
tabs of the tab washer toward the front of the gear housing.
10. Install the propeller bore sleeve on the bearing carrier retainer nut. Failure to install the propeller bore sleeve will result in a
loss of boat performance.

61978





b a - Tab washer
b - Rectangular tab
c - U‑shaped tab
a
c 29392

First 135.5 – 100
Final 285 – 210
slow steady motion.

a - Torque wrench
2989


First 135.5 – 100
Bearing carrier
Final 285 – 210
Water Pump Assembly

assembly.

b - O‑ring
c - Filler block
b
c
48519


b - Retaining ring
48281
NOTE: The faceplate may be reused if there are no grooves other than the impeller sealing ring groove.
5. Install the faceplate over the driveshaft and onto the gear housing.
The new three‑piece design can be used in place of the single‑piece overmolded faceplate.

there are no other grooves other than the impeller sealing ring groove. The fiber gasket may be reused if there is no
damage to the gray neoprene strip or the fiber gasket itself.
a
b - Faceplate
c - Metal gasket
48269
a a - Impeller
b - Drive key
48268
impeller.

4 3
2 1
61965

c- Water pump cover
d
55949




48537


Gear Housing Installation—Left‑Hand Rotation

55958
NOTICE

6. Shift the gear housing into reverse gear and place the shift block into the reverse gear position.

a
48526

splines.
48245

48236
b. Rotate the flywheel clockwise: the propeller shaft should rotate counterclockwise.
f. Rotate the flywheel clockwise and the propeller shaft should rotate clockwise.
a - Rubber cover
48235

Locknuts (M12 x 1.75) (4) 60 – 44.2
Screw (M12 x 35) 75 – 55.3
Anode screw (0.437‑14 x 1.75) 54 – 39.8



a - Fill screw
b - Vent screw
a
48252

Lubricant


Left-Hand Rotation S/N 2B172249 and Above
Gear Housing
Section 6C - Left-Hand Rotation S/N 2B172249 and Above
Table of Contents
Left‑Hand Gear Housing Specifications, S/N 2B172249 Propeller Shaft Disassembly—with Dual Springs in
and Above...................................................................... 6C-2 Actuator Rod......................................................... 6C-32
Gear Housing (Driveshaft)............................................... 6C-10 Forward Gear and Bearing Adapter Disassembly .......... 6C-33
Gear Housing, Propeller Shaft, Counterrotation S/N Bearing Adapter Assembly....................................... 6C-35
2B172249–2B205521...................................................6C-12 Pinion Gear and Driveshaft Removal.............................. 6C-36
Gear Housing, Propeller Shaft, Counterrotation S/N Driveshaft Cleaning and Inspection..........................6C-38
2B205522 and Above...................................................6C-14 Reverse (Front) Gear Removal and Disassembly........... 6C-39
Gear Housing, Propeller Shaft, Counterrotation—SeaPro Cleaning and Inspection........................................... 6C-39
..................................................................................... 6C-16 Gear Housing Inspection................................................. 6C-40
General Service Recommendations................................ 6C-18 Pinion Bearing Installation............................................... 6C-41
Bearings................................................................... 6C-18 Forward Gear Bearing Carrier Assembly.........................6C-42
Shims........................................................................6C-18 Reverse (Front) Gear Assembly ..................................... 6C-43
Seals.........................................................................6C-18 Reverse (Front) Gear Bearing Adapter and Gear
6
Gearcase Removal.......................................................... 6C-19 Installation.................................................................... 6C-45
XL Models with Spacer.................................................... 6C-21 Driveshaft Assembly........................................................ 6C-47
Gearcase Service Inspection...........................................6C-21 Pinion Gear Depth........................................................... 6C-49
Draining and Inspecting Gear Housing Lubricant.....6C-21
Draining and Inspecting Gear Housing Lubricant—
Propeller Shaft Assembly—without Springs in Actuator
Rod...............................................................................6C-52
C
SeaPro Models..................................................... 6C-22 Propeller Shaft Assembly—with Springs in Actuator Rod
Propeller Shaft Inspection........................................ 6C-22 ..................................................................................... 6C-56
Water Pump Removal and Disassembly......................... 6C-23 Shift Shaft Installation...................................................... 6C-62
Cleaning and Inspection........................................... 6C-24 Bearing Carrier Installation.............................................. 6C-63
Oil Seal Carrier Assembly................................................6C-25 Forward Gear Backlash................................................... 6C-65
Removal................................................................... 6C-25 Propeller Shaft Bearing Preload...................................... 6C-66
Disassembly............................................................. 6C-26 Water Pump Assembly.................................................... 6C-68
Bearing Carrier and Propeller Shaft Removal ................ 6C-26 Gear Housing Pressure Test........................................... 6C-70
Shift Shaft Inspection................................................6C-29 Gear Housing Installation—Left‑Hand Rotation...............6C-71
Bearing Carrier Disassembly........................................... 6C-29 Gear Lubricant Filling Instructions................................... 6C-73
Propeller Shaft Inspection and Disassembly................... 6C-30 Filling Gearcase—SeaPro Models...................................6C-74
Propeller Shaft Inspection........................................ 6C-30
Propeller Shaft Disassembly—without Dual Springs in
Actuator Rod......................................................... 6C-31

Left‑Hand Gear Housing Specifications, S/N 2B172249 and Above

Left‑Hand Gear Housing Specifications S/N 2B172249 and above
Water pressure
At WOT 80–300 kPa (11.6–43.5 psi)

7 Loctite 271 Threadlocker Outside diameter of the second propeller shaft oil seal 92-809819
Bearings
Outside diameter of bearing cup
Outside diameter of propeller shaft tapered roller bearing
Lubricant
Forward gear tapered roller bearings
Gear housing
Pinion bearing bore
Oil seal lips
Outside diameter of bearing adapter
Thrust washer and thrust bearing
Bearing retainer
Pocket on cam follower
95 2-4-C with PTFE 92-802859A 1
Propeller shaft seal lips and the cavity between the seals
Bearing carrier O-ring and bearing carrier gear housing contact
surfaces

Special Tools

location, and TDC.
9479

2999
29496
46139
9514
Retaining Nut Wrench 91‑8M0070085
Install locknut onto forward gear hub
55843
Installs the bearing cup into the forward gear bearing adapter
9445

9520
28677
Removes bearings from gears and the driveshaft.
8505
49079
29490


11‑ 24156 Hex Nut
12‑ 34961 Washer
91‑ 29310 Plate
6761
Bearing Cup Driver/Oil Seal Installer Tool 91‑888414T01
Installs bearing carrier cup and seals.

6229
Installs the reverse gear bearing adapter
49522
49261

49265
49263
47416
measurements
8756

B A
56235
60578

Allows pinion measuring gauge to fit the front gear bearing
56254
49549
Preload Driver 91‑8M0071639
Used with torque wrench to check rolling torque of the left‑hand forward gear
assembly
55844
Aids in the installation of the sliding clutch cross pin

48579

48577

48578

49768
46139
46158

inch prop
10805
47536
29497

Notes:


42
11
42
12
14 10
13
31 15
16
17
18
19
34
40
20
21
6
22
35 32
37 23
36 41
38 33
43
39 24
8 7 5
25
26
4
7 27
9 28
29
44 30
23
1
45 3
48386


Torque
1 1 Gearcase
2 1 Plug
3 2 Seal
7 2 Anode
8 1 Screw (M6 x 40) 6.8 60.2 –
10 1 Filler block
12 4 Screw (M6 x 20) 6.8 60.2 –
15 1 Drive key
16 1 Impeller
17 1 Gasket
18 1 Faceplate
19 1 Gasket
20 1 Retaining ring
22 2 Oil seal
23 1 O‑ring (2.175 x 0.103)
24 1 Retainer 135.5 – 100
27 1 Shim
30 1 Shim
31 1 Driveshaft
32 1 Pinion gear
33 1 Nut (0.625‑18) 101.7 – 75
34 1 Shift shaft
35 1 Retaining ring
36 1 Oil seal
37 1 Washer
39 1 O‑ring
40 1 E‑ring
41 1 Washer
42 2 O‑ring (0.796 x 0.139)
43 1 Screw (0.437‑14 x 1.750) 54 – 39.8
44 1 Anode
45 1 Vent screw 11.3 100 –

Gear Housing, Propeller Shaft, Counterrotation S/N 2B172249–2B205521
19 22 23
4
5
21
20
3
17 18
10 15 16
9
8
5 6 7
4
2 3
12 13
11
14
25 29
28
22
23
24 27 26
58397

Gear Housing, Propeller Shaft, Counterrotation S/N 2B172249–2B205521

Torque
1 1 Gear housing
2 1 Reverse gear adapter
4 2 Thrust washer
5 2 Thrust bearing
6 1 Retaining ring
7 1 Needle bearing
8 1 Reverse gear (25 teeth)
9 1 Cam follower
10 1 Shift cam
11 1 Tab washer
14 1 Seal
17 1 Cross pin
18 1 Forward gear (25 teeth)
20 1 Spacer shim
21 1 O‑ring (3.975 x 0.210)
22 2 Thrust washer
23 2 Thrust bearing
26 1 Fill screw 11.3 100 –
27 1 Oil seal
28 1 Needle bearing
29 1 Oil seal

Gear Housing, Propeller Shaft, Counterrotation S/N 2B205522 and Above
23
1
21
19
19
24
16 17 22
15 18
12 20
18
2
6
14
5 13
7 3 11
8
9
10 35
4 36
34
31
29
27
28
26 32
30
33
25
62369

Gear Housing, Propeller Shaft, Counterrotation S/N 2B205522 and Above

Torque
1 1 Gearcase housing
2 1 Reverse gear
3 1 Retaining ring
4 1 Thrust washer
5 1 Bearing cup
6 1 Tapered roller bearing
7 1 Thrust bearing
8 1 Thrust washer
10 1 Reverse gear bearing adapter
11 1 Cam follower
12 1 Shift cam
16 1 Cross pin
17 1 Forward gear
19 2 Bearing cup
21 1 Thrust washer
22 1 Locknut
23 1 Set screw (half dog point) 1.7 15 –
24 1 Spacer shim
26 1 O‑ring (3.975 x 0.210)
27 1 Bearing cup
30 1 Thrust spacer
31 2 Oil seal
32 1 Fill screw 11.3 100 –
33 1 Seal
34 1 Tab washer
36 1 Retainer 285 – 210.2

Gear Housing, Propeller Shaft, Counterrotation—SeaPro
23
1
21
19
19
24
16 17 22
38
37 15 18
12 20
18
2
6
14
5 13
7 3 11
8
9
10 35
4 36
34
43 40 31
42 39 29
41 27
28
26 32
30
33
25
58605

Gear Housing, Propeller Shaft, Counterrotation—SeaPro

Torque
1 1 Gearcase housing
2 1 Reverse gear
3 1 Retaining ring
4 1 Thrust washer
5 1 Bearing cup
7 1 Thrust bearing
8 1 Thrust washer
10 1 Reverse gear bearing adapter
11 1 Cam follower
12 1 Shift cam
16 1 Cross pin
17 1 Forward gear
19 2 Bearing cup
21 1 Thrust washer
22 1 Locknut
23 1 Set screw (half dog point) 1.7 15 –
24 1 Spacer shim
26 1 O‑ring (3.975 x 0.210)
27 1 Bearing cup
30 1 Thrust spacer
31 2 Oil seal
32 1 Fill screw 11.3 100 –
33 1 Seal
34 1 Tab washer
36 1 Retainer 285 – 210.2
37 1 Magnetic drain screw 11.3 100 –
38 1 Seal
39 1 Actuator kit (2B384875 and up)
41 1 Cross pin
42 2 Spring
43 1 Pin


Bearings
be replaced.

87 Bearings 92-858064K01
Lubricant
Shims
Seals

95 2-4-C with PTFE 92-802859A 1

Gearcase Removal
! WARNING

b a- Tab washer
f
d- Rear thrust hub
e- Propeller shaft
f- Front thrust hub
d c e
48808
a - Rubber cover
48235

a - Screw
48236
48245
off.


2
3
6 3
1
4
4
5
4
5
5
71422
Torque
2 2 Dowel pin
4 5 Washer
5 5 M12 hex locknut 60 – 44.2
6 1 Screw M12 x 160 30 – 22.1


a - Fill screw
b - Vent screw
a
48252
Draining and Inspecting Gear Housing Lubricant—SeaPro Models

a b
62153
a - Upper vent plug



b a - Propeller shaft
b - Dial indicator, checking for runout
61941
Propeller Shaft
Runout 0.152 mm (0.006 in.)



c- Water pump cover
d
55949


a a - Impeller
b - Drive key
48268
7. Remove the water pump faceplate and both gaskets from the gear housing.
a
a - Fiber gasket (gray neoprene strip faces up)
b - Faceplate
c - Metal gasket
48269

2. Inspect the stainless steel gasket coated surface for scratches or damage. If the coating is scratched or damaged, replace
the stainless steel gasket.

a
b - Coating
b
46007
3. Inspect the faceplate for grooves or rough surfaces. Replace the faceplate if damage is found.
4. Inspect the fiber gasket. Replace the fiber gasket if damage is found.

55952
b a - Impeller
55953

Removal

b - Retaining ring
48281


c - Protective pad
a
c
b
48284

b - O‑ring
48291
Disassembly



c - Lock tabs
a
b
c
48306

a
55955

48311

a - Long jaws
a b - Puller bolt
b c - Thrust hub
c 62118

8. Remove the shift shaft bushing retaining ring.
a - Shift shaft
a b - Shift shaft bushing
c - Retaining ring
b
48315

a
48317
11. Remove the propeller shaft, cam follower, and shift cam by pulling the propeller shaft straight out of the gear housing.
NOTE: Take care not to lose the shims as the propeller shaft is removed from the gear housing.
Do not jerk the propeller shaft out of the gear housing. If the propeller shaft will not come out, proceed as follows:



1. Remove the propeller shaft oil seals from the bearing carrier with a drift punch.
a - Drift punch
b - Seals (2)
a c - Bearing carrier
55849
2. Place the bearing carrier in a vise, clamping on the reinforcing rib.

3. Remove the bearing cup using a slide hammer puller.
a a- Slide hammer puller

b- Bearing cup (inside of bearing carrier)
b
c- Bearing carrier
d- Reinforcing rib
3141


1. Remove the bearing, thrust washers, thrust spacer, and shift cam from the propeller shaft.
b c d e
a
55745
a- Propeller shaft
b- Bearing
c- Thrust washer
d- Thrust spacer
e- Shift cam
3. Inspect the area of the oil seals for grooves. Replace the propeller shaft if grooves are found.
overheating. Replace the shaft and corresponding bearing if any of the previous mentioned conditions are found.
a. Position the propeller shaft roller bearing surfaces on balance wheels or V‑blocks. Use a dial indicator at the front
edge of the propeller splines. Rotate the propeller shaft. Dial indicator movement more than the specification requires
the propeller shaft to be replaced.
a - Dial indicator location

b - Bearing surface
b b
61942
Propeller Shaft
Runout 0.152 mm (0.006 in.)

Propeller Shaft Disassembly—without Dual Springs in Actuator Rod

a a - Awl
55739
a - Cross pin
b - Clutch
b
a
55740

a- Forward gear assembly

b- Clutch
d- Cam follower
c
d
a b 55741
shift cam.

8. Remove the forward gear assembly.
a
a - Forward gear assembly
55742
Propeller Shaft Disassembly—with Dual Springs in Actuator Rod

a a - Awl
55739
a - Cross pin
b - Clutch
b
a
55740


6. Disconnect the clutch actuator rod from the cam follower. Remove the spring‑retaining cross pin from the clutch actuator
rod and remove the springs.
e f
c
d
a b
60745
a- Forward gear assembly

b- Clutch
d- Cam follower
e- Spring‑retaining cross pin
f- Springs (2)
7. Clean the cam follower, and the clutch actuator rod and components in a mild solvent. Dry with compressed air and inspect
the components for wear or damage. Replace worn or damaged components.
8. Remove the forward gear assembly.
a
a - Forward gear assembly
55742
Forward Gear and Bearing Adapter Disassembly

1. Clamp the propeller shaft in a soft jaw vice.
2. Install the clutch onto the propeller shaft.

3. Install the cross pin through the clutch and propeller shaft.
a- Soft jaw vice

b- Propeller shaft
d c- Cross pin
d- Clutch
c
b
a
55760
4. Install the forward gear assembly onto the propeller shaft/clutch.

5. Loosen the set screw in the locknut.
a a - Locknut
b - Set screw
61943
6. Using the retaining nut wrench, loosen the locknut.
a- Breaker bar
b- Retaining nut wrench
c- Set screw
b a d- Forward gear
c
55750

7. Remove the locknut from the forward gear assembly.

8. Remove the tapered roller bearings, and thrust washer from the forward bearing adapter.
e a- Forward gear (31 teeth)

b- Tapered roller bearing
c- Bearing adapter assembly (includes bearing cups)
d d- Thrust washer
e- Locknut
f- Special set screw
f b
55763
9. Remove the special set screw and inspect the brass point. Replace if necessary.
10. Inspect the clutch dog teeth on the forward gear for signs of wear. Replace the gear and clutch if necessary.
11. Inspect the forward gear clutch dog teeth for damage. Replace if necessary.
12. Inspect the thrust washer for pitting, rust, or signs of discoloration. Replace if any of these conditions are found.
13. Carefully inspect the tapered roller bearings for pitting, rust, or signs of discoloration. Replace the bearing if any of these
Bearing Adapter Assembly

1. Inspect the bearing cups in the bearing adapter. If the bearing cups require replacement, use a drift punch to drive the
bearing cups out of the adapter.
a - Drift punch
b - Bearing cup
c - Bearing adapter
a
b
56266

2. Use bearing cup driver 91‑8M0073870 to press the new bearing cups into the bearing adapter with the numbers/letters
facing into the bearing adapter.
a - Bearing cup driver

b - Bearing adapter
a
56267

48340


driveshaft.

the 18 rollers.
a - Wood block
b a
48341
9. Remove the pinion gear and reverse (front) gear assembly from the gear housing. Refer to Reverse Gear Removal and
Disassembly.
covers.
a - Upper bearings
a
56202



b - Pilot washer
c - Driver rod
48344


! WARNING
b a - Splines
a c a
56198

Reverse (Front) Gear Removal and Disassembly

1. Remove the reverse (front) gear from the gear housing.
39779
rust, or discoloration. Replace the components if any of these conditions are found.
a - Thrust bearing
a b - Thrust washer
c - Bearing adapter
c
39782
3. Use the two jaw puller, a threaded rod, washer, and guide plate to remove the reverse (front) gear bearing adapter.
a a- Threaded rod
c b- Nut
b c- Washer
d d- Guide plate
e- Two jaw puller head
e
39787


1. Clean the reverse (front) gear and bearing with a mild solvent. Dry with compressed air. Do not spin the bearing.
! WARNING

3. Inspect the clutch dogs on the reverse (front) gear for damage. Replace the reverse (front) gear if damage is found.
a - Gear teeth
b - Clutch dogs
39789
4. Inspect the tapered roller bearing and race on the inside of the reverse (front) gear. Inspect the bearing surface on the
propeller shaft. If either the bearing, race, or the bearing surface of the propeller shaft are pitted, grooved, worn unevenly,
discolored, or has embedded particles, replace the propeller shaft and tapered bearing/race in the reverse (front) gear.
5. Remove the retaining ring securing the propeller shaft bearing.
6. Remove the thrust washer, bearing cup, and tapered roller bearing from the reverse (front) gear.
e b
f d c
61945
a- Propeller shaft
b- Retaining ring
c- Thrust washer
d- Bearing cup
e- Tapered roller bearing
f- Reverse (front) gear


a
49365
holes.

a- Puller rod
b- Puller plate
a c- Pilot washer
f e- Mandrel
b f- Hex nut
e
48970


Forward Gear Bearing Carrier Assembly

1. Lubricate the outside diameter of the bearing cup with High‑Performance Gear Lubricant.
2. Press the numbered side of the bearing cup into the bearing carrier until the bearing cup is seated in the bearing carrier.
a - Bearing carrier
b - Driver
c - Bearing cup
b
c
55786

87 Outside diameter of bearing cup 92-858064K01
Lubricant

3. Ensure that the bearing carrier bore is clean and dry.
4. Install the first seal onto the long shoulder side of the oil seal driver mandrel. Verify that the seal lip faces away from the
mandrel shoulder. Press the seal into the bearing carrier until the mandrel contacts the bearing carrier.
a - Oil seal
b - Bearing carrier
c - Mandrel
a
b
55776

5. Apply Loctite 271 Threadlocker to the outside diameter of the second propeller shaft oil seal.

6. Install the second seal onto the short shoulder side of the oil seal driver mandrel. Verify that the seal lip faces toward the
mandrel shoulder. Press the seal into the bearing carrier until the mandrel driver contacts the bearing carrier.
a - Oil seal
b - Bearing carrier
c - Mandrel
a
b
55777

7 Loctite 271 Threadlocker Outside diameter of the second propeller shaft oil seal 92-809819

7. Apply 2‑4‑C with PTFE to the oil seal lips.

95 2-4-C with PTFE Oil seal lips 92-802859A 1
Reverse (Front) Gear Assembly

1. Lubricate the outside diameter of the propeller shaft tapered roller bearing with High‑Performance Gear Lubricant.

87 Outside diameter of propeller shaft tapered roller bearing 92-858064K01
Lubricant
2. Assemble the reverse (front) gear as follows:
a. Install the tapered roller bearing into the reverse (front) gear, as shown.
a a - Tapered roller bearing

b - Reverse (front) gear
61948

b. Insert the bearing cup over the tapered roller bearing and press until it is seated against the gear.
a a - Bearing cup
b - Tapered roller bearing
c - Reverse (front) gear
b
c
61949
c. Install the thrust washer over the bearing cup, as shown.
a a - Thrust washer
b - Bearing cup
b
61950
d. Secure the thrust washer with the retaining ring, as shown.
a - Retaining ring
b - Thrust washer
61951

61952
Reverse (front) gear assembly
Reverse (Front) Gear Bearing Adapter and Gear Installation

1. Lubricate the outside diameter of the bearing adapter with 2‑4‑C with PTFE.
2. Position the bearing adapter into the gear housing bore.
a - Bearing adapter
49253

95 2-4-C with PTFE Outside diameter of bearing adapter 92-802859A 1
3. Install the reverse (front) gear bearing mandrel into the bearing adapter.
a - Mandrel
b - Bearing adapter
b
49535
4. Install the pilot ring onto the driver tool and install the tool assembly into the gear housing. Verify the pilot ring is seated on
the gearcase ledge.
5. Thread the adapter into the gearcase bearing carrier retainer threads and install the driver screw into the adapter.
6. Secure the adapter and thread the driver screw in until the bearing adapter is seated in the gear housing.

IMPORTANT: Do not overtighten the driver screw. Overtightening the driver screw will damage the bearing inside the
bearing adapter.
c d a- Driver screw
a b b- Adapter
c- Driver tool
d- Installer pilot
e- Mandrel
f- Bearing adapter
e
f
62167

IMPORTANT: Bearing cup/adapter installation tool 91‑18605A2 can be used to install the right‑hand forward gear bearing
race and the left‑hand reverse gear bearing adapter if retainer installer tool 91‑8M0048109 and installer pilot
91‑8M0048035 are used.
7. Remove the adapter, pilot ring, and driver tool from the gear housing.
8. Install the thrust washer onto the bearing adapter.
9. Lubricate the thrust bearing and thrust washer with 2‑4‑C with PTFE and install the bearing onto the thrust washer. The
2‑4‑C with PTFE will help keep the thrust washer and thrust bearing in position during assembly.
a - Thrust bearing
b - Thrust washer
a c - Bearing adapter
b c
39961

95 2-4-C with PTFE Thrust washer and thrust bearing 92-802859A 1
10. Install the reverse (front) gear onto the bearing adapter.
a - Reverse (front) gear

b - Thrust bearing and thrust washer
a
39962

Driveshaft Assembly
driveshaft.
driveshaft.
a- Used pinion nut

a b- Driveshaft
c- Bearing
e
48776

Lubricant

driveshaft.
a- Pinion nut
b- Driveshaft
c
d e
f
48778

Lubricant


9. Position the pinion gear into the gear housing with the teeth of the pinion gear meshed with the reverse (front) gear.
checked.
NOTE: After the shimming process is completed, a new pinion nut must be installed. Refer to Pinion Gear Depth for final
installation information.
a a- Driveshaft
b- Pinion gear
g c- Washer
d- Pinion nut
f
e- Reverse (front) gear
e
b
c
d 56244


b- Bearing retainer
b
c
d
e
f 49267




b- Torque wrench
c- Socket (7/8 in.)
b d- Breaker bar
a
a
d 48797

the driveshaft rolling torque is not within specification, the shim under the upper tapered roller bearing cup will need to be
upper bearing cup. If the driveshaft rolling torque is too low, add shims from under the upper bearing cup.

Pinion Gear Depth

IMPORTANT: The reverse (front) gear assembly pilots the end of the pinion gauge and must be installed in the gear housing
when checking pinion gear depth. An inaccurate measurement will be obtained without the forward gear assembly installed.
IMPORTANT: Do not assemble the propeller shaft until after the pinion gear depth and forward gear backlash are within
specifications.
bearings.

d a- Coupler
b- Threaded rod
f- Set screw (2)
f g- Bolt
g h- Spring
m i- Thrust washer
h j- Thrust bearing
b k- Adapter
i l- Plate
j m- Nut
a k
l
13288

a
a - Bolt head
b - Nut
7275
6. Assemble the pinion gear locating tool, as shown.
a. Install the gauging block with the numbers toward the arbor handle.
b. Position the split collar and gauging block against the pinion gauge adapter tool. Tighten the split collar retaining
screw.
c. Place the adapter tool on the arbor handle with side B toward the front gear.
d a- Arbor handle
2
3
1
b- Screw (2)
7 5
a 6
e- Split collar
b f
• Side B toward the front gear
b 56331


NOTE: Pinion gear locating tool 91‑12349A05 may be used to determine pinion depth if a pinion gauge adapter tool is
installed on the end of the arbor allowing it to properly match with the reverse gear bearing diameter. The part number for
the pinion gear location tool upgrade kit is 91‑8M0089165. This kit includes a pinion gauge adapter tool and a #4 and #5
locating disc.
7. Insert the pinion gear locating tool into the reverse (front) gear assembly. Position the correct gauging block flat number
under the pinion gear, as shown.
a - Gauging block
a
7279
150 EFI 1.92:1 (13/25) 4 4
a b - Access hole
b
7282

is less than 0.64 mm (0.025 in.), add shims under the upper driveshaft bearing race.

13. Check the pinion gear depth after making a change to the pinion gear shimming.
d a- Feeler gauge
c- Pinion gear
7283
14. If the bearing preload tool was installed for Pinion Gear Depth, it should remain in position for the Forward Gear
Backlash procedure later in this section.


18. Install the flat washer and the new pinion nut onto the driveshaft with the flat side of the nut facing away from the pinion
gear. Hand‑tighten the pinion nut.

b- Torque wrench
c- Socket (7/8 in.)
b d- Breaker bar
a
a
d 48797

Propeller Shaft Assembly—without Springs in Actuator Rod


1. Lubricate the two tapered roller bearings with High‑Performance Gear Lubricant.
2. Install one tapered roller bearing onto the forward gear.
3. Install the bearing adapter onto the tapered roller bearing with the flange side toward the forward gear.
4. Install the second tapered roller bearing into the bearing adapter.
5. Install the thrust washer onto the forward gear.
6. Thread the locknut onto the forward gear until hand‑tight.
e a- Forward gear
c- Bearing adapter assembly (with bearing cups)
d d- Thrust washer
e- Locknut
f b
55765

87 Forward gear tapered roller bearings 92-858064K01
Lubricant
7. Clamp the propeller shaft in a soft jaw vise.
a- Soft jaw vice

b- Propeller shaft
d c- Cross pin
d- Clutch
c
b
a
55760
11. Set the bearing preload using the following procedure:

a. Using the retaining nut wrench, tighten the locknut to the specified torque to preload the bearings.
a- Torque wrench
c- Special set screw
d- Forward gear
b a
c
55767

Forward gear assembly locknut 67.8 – 50

b. Using the preload driver tool, rotate the bearing carrier four rotations and then check the rolling torque.
IMPORTANT: Rotate the bearing carrier at 50–60 RPM to obtain an accurate rolling torque reading.
a- Torque wrench
a b- Adapter
b c- Preload driver
d- Bearing carrier
c
d
55841

Forward gear bearing rolling torque 1.1–2.3 10–20 –

c. If the rolling torque is not within specification, increase or decrease the torque on the locknut in step a, then check the
rolling torque in step b.
d. Tighten the special set screw to the specified torque using a 3/32 hex driver bit.

Special set screw 1.7 15 –

12. Install the forward (rear) gear assembly onto the propeller shaft.
a
b - Propeller shaft
b
55768
13. Install the clutch as shown with the hole aligned with the slot in the propeller shaft.
14. Install the actuator rod into the slot in the cam follower.
15. Install the actuator rod/cam follower into the propeller shaft.
16. Install the cross pin through the clutch, actuator rod, and propeller shaft.
a
a- Clutch
b- Actuator rod
b c c- Cam follower
d- Cross pin
d
55769
a a - Cross pin (hidden)

b - Retaining spring
b
55770

20. Install the thrust spacer, thrust washers, and bearing onto the propeller shaft.
b c d
a
55771
a- Propeller shaft
b- Bearing
c- Thrust washer
d- Thrust spacer
e- Shift cam

21. Install the forward (rear) gear shims that were removed during disassembly.
62125
Install shims
22. Insert the assembled propeller shaft into the gear housing.
• Look down the shift shaft bore and make sure the hole in the shift cam is aligned with the center of the shift shaft
bore.
Propeller Shaft Assembly—with Springs in Actuator Rod

1. Lubricate the two tapered roller bearings with High‑Performance Gear Lubricant.
2. Install one tapered roller bearing onto the forward gear.
3. Install the bearing adapter onto the tapered roller bearing with the flange side toward the forward gear.
4. Install the second tapered roller bearing into the bearing adapter.
5. Install the thrust washer onto the forward gear.

6. Thread the locknut onto the forward gear until hand‑tight.
e a- Forward gear
c- Bearing adapter assembly (with bearing cups)
d d- Thrust washer
e- Locknut
f b
55765

87 Forward gear tapered roller bearings 92-858064K01
Lubricant
7. Clamp the propeller shaft in a soft jaw vice.
a- Soft jaw vice

b- Propeller shaft
d c- Cross pin
d- Clutch
c
b
a
55760
11. Set the bearing preload using the following procedure:

a. Using the retaining nut wrench, tighten the locknut to the specified torque to preload the bearings.
a- Torque wrench
c- Special set screw
d- Forward gear
b a
c
55767

Forward gear assembly locknut 67.8 – 50

b. Using the preload driver tool, rotate the bearing carrier four rotations and then check the rolling torque.
IMPORTANT: Rotate the bearing carrier at 50–60 RPM to obtain an accurate rolling torque reading.
a- Torque wrench
a b- Adapter
b c- Preload driver
d- Bearing carrier
c
d
55841

Forward gear bearing rolling torque 1.1–2.3 10–20 –

c. If the rolling torque is not within specification, increase or decrease the torque on the locknut in step a, then check the
rolling torque in step b.
d. Tighten the special set screw to the specified torque using a 3/32 hex driver bit.

Special set screw 1.7 15 –

12. Install the forward (rear) gear assembly onto the propeller shaft.
a
b - Propeller shaft
b
55768
13. Install the clutch as shown with the hole aligned with the slot in the propeller shaft.
14. Insert the two compression springs into the clutch actuator rod and secure with the spring‑retaining cross pin.
c
a
60664
a - Clutch actuator rod

b - Compression springs (2)
c - Spring‑retaining cross pin
15. Use a beveled cross pin tool to separate the two compression springs. Install the pin stop installation tool into the actuator
rod using the actuator assembly tool and mallet. Unscrew the pin pull tool from the pin stop installation tool. The pin stop
installation tool should remain in the actuator.
d
a
c d c
b
60666
a- Actuator rod
b- Beveled cross pin tool
c- Pin stop installation tool (part of actuator assembly tool)
d- Pin pull tool (part of actuator assembly tool)



b - Cam follower
60752
17. Insert the clutch actuator rod/cam follower assembly into the end of the propeller shaft. Position the actuator rod far enough
into the propeller shaft to align the pin stop installation tool in the actuator rod with the cross pin hole in the clutch.
a
b e
60753
c d
a- Clutch
b- Actuator rod
c- Cross pin hole
d- Pin stop installation tool (in actuator rod)
e- Cam follower
18. Insert the pin pull tool into the cross pin hole and thread into the pin stop installation tool.
19. Turn the propeller shaft/clutch assembly over and insert the cross pin into the open cross pin hole in the clutch. Align the
cross pin so the flat surfaces of the pin will contact each compression spring in the actuator rod. Using a mallet, drive the
cross pin into the hole until it is fully seated in the clutch housing, and the actuator assembly tool falls from the clutch
assembly.
b c
a
a
60754
a - Pin pull tool (part of actuator assembly tool)

b - Cross pin
c - Pin stop installation tool (part of actuator assembly tool)


a a - Cross pin (hidden)

b - Retaining spring
b
55770
23. Install the thrust spacer, thrust washers, and bearing onto the propeller shaft.
b c d
a
55771
a- Propeller shaft
b- Bearing
c- Thrust washers
d- Thrust spacer
e- Shift cam

24. Install the forward (rear) gear shims that were removed during disassembly.
62125
Install shims
25. Insert the assembled propeller shaft into the gear housing.
• Look down the shift shaft bore and make sure the hole in the shift cam is aligned with the center of the shift shaft
bore.


1. Verify that the forward (rear) spacer shim is in place in the gear housing.
2. Apply Perfect Seal to the outside diameter of the shift shaft seal and install the seal into the shift shaft bushing with the seal
lip facing up toward the powerhead.

b - Bushing
c - O‑ring
a
134
b
c
95
48440

a
a- Seal
b c- O‑ring
d- E‑ring
c e- Shift shaft
48449

a- Shift shaft
a
c- Rubber washer
b d- Retaining ring
d
c
55954
Bearing Carrier Installation

1. Apply 2‑4‑C with PTFE to the propeller shaft seal lips and the cavity between the seals.
a - Bearing carrier
a b - Propeller shaft seals
55845

95 2-4-C with PTFE Propeller shaft seal lips and the cavity between the seals 92-802859A 1
2. Lubricate the bearing carrier O‑ring with 2‑4‑C with PTFE. Install the O‑ring onto the bearing carrier.
3. Apply 2‑4‑C with PTFE onto the bearing carrier gear housing contact surfaces.
b a - O‑ring
b - Gear housing contact surfaces
a
61960


Bearing carrier O-ring and bearing carrier gear housing
95 2-4-C with PTFE 92-802859A 1
contact surfaces
4. Install the bearing carrier onto the propeller shaft assembly inside of the gear housing. Align the tab on the forward gear
bearing assembly with the notch in the bearing carrier.
b
a
d
c
61961
a- Bearing carrier
b- O‑ring
c- Tab on the forward gear bearing assembly
d- Notch in the bearing carrier

a- Keyed washer
b a
b- Index tab
c- Index tab
d- Locking tab
c
d
d
56250

a- O‑ring
b- Retainer nut
d- Torque wrench
a b c d
95
48512


Retainer nut 285 – 210.2

1. Install the dial indicator adapter to the gear housing. lnstall the backlash indicator rod and dial indicator as shown.
c
d- Dial indicator
e- Threaded rod
d
e
56195



3. Rotate the shift shaft into the forward (rear) gear position.
4. Rotate the shift shaft into the neutral position.
5. While holding the shift shaft in the neutral position, rotate the driveshaft approximately 30°, reposition the flag, and then
rotate the shift shaft counterclockwise toward the forward gear position. Ideally, the shift shaft should not go into the
forward gear position. The clutch dogs should butt against the forward gear clutch dogs. Hold the shift shaft firmly in this
position.
6. While firmly holding the clutch against the forward gear with the shift shaft, lightly rotate the driveshaft back‑and‑forth.

0.533–0.660 mm
1.92:1 (13/25)
(0.021–0.026 in.)
8. If the backlash is less than the minimum specification, install a thicker spacer shim in front of the bearing adapter. If the
backlash is more than the maximum specification, install a thinner spacer shim in front of the bearing adapter.
9. After all backlash measurements are correct, bend the locking tab washer tab into the retainer nut. Bend the remaining
tabs of the tab washer toward the front of the gear housing.
10. Install the propeller bore sleeve on the bearing carrier retainer nut. Failure to install the propeller bore sleeve will result in a
loss of boat performance.

61978





b a - Tab washer
b - Rectangular tab
c - U‑shaped tab
a
c 29392

First 135.5 – 100
Final 285 – 210
slow steady motion.

a - Torque wrench
2989


First 135.5 – 100
Bearing carrier
Final 285 – 210
Water Pump Assembly

assembly.

b - O‑ring
c - Filler block
b
c
48519


b - Retaining ring
48281
there are no grooves other than the impeller sealing ring groove. The fiber gasket may be reused if there is no damage to
the gray neoprene strip or the fiber gasket itself.

5. Install a new metal gasket, faceplate, and fiber gasket.
a
a - Fiber gasket (gray neoprene strip faces up)
b - Faceplate
c - Metal gasket
48269
a a - Impeller
b - Drive key
48268
impeller.
4 3
2 1
61965


c- Water pump cover
d
55949



48537


Gear Housing Installation—Left‑Hand Rotation

55958
NOTICE
6. Shift the gear housing into reverse gear and place the shift block into the reverse gear position.

a
48526

splines.

48245
48236
b. Rotate the flywheel clockwise: the propeller shaft should rotate counterclockwise.
f. Rotate the flywheel clockwise and the propeller shaft should rotate clockwise.

a - Rubber cover
48235

Locknuts (M12 x 1.75) (4) 60 – 44.2
Screw (M12 x 35) 75 – 55.3
Anode screw (0.437‑14 x 1.75) 54 – 39.8



a - Fill screw
b - Vent screw
a
48252

Lubricant




IMPORTANT: Never add lubricant to gear housing without first removing the vent plug.


62154

Lubricant


Notes:

Right-Hand Rotation (Pro XS)
Gear Housing
Section 6D - Right-Hand Rotation (Pro XS)
Table of Contents
Gear Housing Specifications (Pro XS 4.8 in.) ...................6D-2 Disassembly............................................................. 6D-35
Gear Housing (Driveshaft)................................................. 6D-8 Assembly.................................................................. 6D-36
Gear Housing, Propeller Shaft.........................................6D-10 Shift Spool Assembly.......................................................6D-37
General Service Recommendations................................ 6D-12 Inspection................................................................. 6D-37
Bearings................................................................... 6D-12 Disassembly............................................................. 6D-37
Shims........................................................................6D-12 Reassembly..............................................................6D-38
Seals.........................................................................6D-12 Shift Shaft Removal, Disassembly and Inspection,
Gearcase Removal ......................................................... 6D-13 Assembly......................................................................6D-38
XL Models with Spacer.................................................... 6D-15 Removal................................................................... 6D-38
Gearcase Service Inspection...........................................6D-15 Disassembly and Inspection.....................................6D-39
Draining and Inspecting Gear Housing Lubricant.....6D-15 Pinion Bearing Removal.................................................. 6D-39
Propeller Shaft Inspection........................................ 6D-16 Gear Housing Inspection................................................. 6D-40
Gear Housing Pressure Test........................................... 6D-17 Pinion Bearing Installation............................................... 6D-40
6
Bearing Carrier Removal, Disassembly, and Assembly.. 6D-17 Front Gear Bearing Cup Installation................................ 6D-41
Cleaning/Inspection.................................................. 6D-19 Driveshaft Bearing Rolling Torque and Pinion Gear Height
Disassembly............................................................. 6D-19 ..................................................................................... 6D-41
Assembly.................................................................. 6D-22
Water Pump Removal and Disassembly......................... 6D-25
Driveshaft and Pinion Gear Installation.................... 6D-42
Driveshaft Bearing Rolling Torque............................6D-43
D
Cleaning and Inspection........................................... 6D-26 Checking and Adjusting Pinion Gear Height with
Oil Seal Carrier................................................................ 6D-27 Pinion Gear Locating Tool 8M0089163................ 6D-44
Removal................................................................... 6D-27 Shift Shaft Installation...................................................... 6D-45
Disassembly............................................................. 6D-28 Propeller Shaft Assembly................................................ 6D-46
Driveshaft Removal, Inspection, Disassembly, and Propeller Shaft Installation...............................................6D-47
Assembly......................................................................6D-28 Driveshaft and Pinion Gear Installation........................... 6D-48
Removal................................................................... 6D-28 Front Gear Backlash (Forward)....................................... 6D-49
Inspection................................................................. 6D-30 Rear Gear Backlash........................................................ 6D-51
Disassembly............................................................. 6D-30 Propeller Shaft Bearing Preload...................................... 6D-52
Assembly.................................................................. 6D-31 Bearing Carrier Final Installation..................................... 6D-54
Propeller Shaft Assembly and Front Gear Bearing Cup.. 6D-32 Oil Seal Carrier Installation.............................................. 6D-56
Removal................................................................... 6D-32 Water Pump Installation...................................................6D-57
Propeller Shaft Disassembly.................................... 6D-33 Gear Housing Pressure Test........................................... 6D-58
Inspection................................................................. 6D-34 Checking Gearcase Operation........................................ 6D-59
Front Gear Inspection, Disassembly, Assembly.............. 6D-34 Gear Housing Installation................................................ 6D-59
Inspection................................................................. 6D-34 Gear Lubricant Filling Instructions................................... 6D-62

Gear Housing Specifications (Pro XS 4.8 in.)

Description Specification
Gearcase capacity 970 ml (32.8 fl oz)
Front gear backlash 0.482–0.660 mm (0.019–0.026 in.)
Rear gear backlash 1.27–1.47 mm (0.050–0.058 in.)
Water pressure
At WOT 80–300 kPa (11.6–43.5 psi)
Gear housing pressure (without gear lubricant, 5 minutes without leakage) 103.4 kPa (15 psi)

7 Loctite 271 Threadlocker 92-809819
Pinion nut threads
27 Bellows Adhesive Pinion washer 92-86166Q1
Bearings
Tapered bearing race bore
Bearing bore in carrier
Inside diameter of the driveshaft tapered bearings
87 Outside diameter of front gear bearing surface 92-858064K01
Lubricant
Inside diameter of front gear
Pinion bearing bore
Front gear bearing cup bore
Gear housing
Oil seal lips and between oil seals
Retainer threads
Shift shaft cover O-ring and shift shaft seal lips
Driveshaft bearing retainer threads
Bearing carrier retainer nut threads
95 2-4-C with PTFE 92-802859A 1
Carrier O-ring, forward and aft outside diameters of bearing
carrier, gearcase area where carrier will seat, and space
between carrier oil seals
Bearing carrier retainer nut threads and corresponding gear
housing threads
Oil seal carrier oil seal lips, space between oil seals, and O-ring
Flat surface of the driveshaft key
134 Loctite 380 Outside diameter of bearing carrier oil seal Obtain Locally

Special Tools

location, and TDC.
9479

2999
Dial Indicator Holding Tool 91‑ 89897
29496
29497
46139
9514
Aids in the removal of various engine components; use with puller jaws
6761

Removes bearings from gears and the driveshaft
8505
Bearing Puller Assembly 91‑ 83165T
Removes bearings, races and bearing carriers
3610
29490
Seal Driver Guide 91‑8M0147116
Aids in the installation of bearing carrier seals
29590
Bearing Removal and Installation Kit 91‑ 31229A 7

Installs and removes the bearings in all gearcases
11‑ 24156 Hex Nut
12‑ 34961 Washer
91‑ 15755T Bearing Carrier
91‑ 29310 Plate
91‑32336 Driver Needle Bearing
91‑36379 Puller/Head Gear
91‑37292 Roller Bearing
91‑ 37323 Driver Head Rod
2966
91‑ 38628T Puller/Driver Head
91‑52393T Driver Needle Bearing
91‑52394 Head Pull Rod

Installs bearing carrier cup and seals

6229
Bearing Cup Driver 91‑885592T
Installs reverse gear bearing cup
29492
Holds driveshaft during pinion nut removal on the Verado models
28677
Pinion Nut Wrench 91‑ 61067T03
Holds the pinion nut when removing the pinion gear and driveshaft
29501
Provides a hex surface to turn the propeller shaft.
10805
9520
47416

Guide Plate 91‑816243
Centers the rod used to drive in the forward gear bearing on a standard rotation
gearcase and the reverse gear bearing on a counter rotation gearcase
4481
Driver Head 91‑ 36569T
Used in pinion gear and bearing installation.
29499
Driver Rod 91‑ 37323
Propeller Shaft Holder 8M0075944
Stabilizes propeller shaft
39510

B A
56235
Aids in checking gear backlash.
46158

Notes:


45
44
33 45
32
33 16
31 14
23
12 15
15
34
11
42 30 41 13
2 35 28
17
29
24
43 18
26
36 27 22
37 19
25
38 21
20
39
10
40 3 6
4
3
4
5 1
7 8
67525


Torque
1 1 Gear housing
2 1 Filler block
3 2 Dowel pin
4 2 Anode
5 1 Screw (M6 x 40) 6.8 60.2 –
6 1 Nut (M6) 6.8 60.2 –
7 1 Plug assembly 6.8 60.2 –
8 1 Seal
9 1 Anode kit
10 1 Screw (0.437‑14 x 1.75) 54 – 40
11 1 Cover assembly
12 1 Oil seal
13 1 O‑ring
14 1 Retaining ring
15 4 Screw 6.8 60.2 –
16 1 Washer
17 1 Gasket
18 1 Shift shaft
19 1 Pinion gear
20 1 Nut (0.625‑18) 101.7 – 75
21 1 Washer
22 1 Bearing assembly
23 1 Driveshaft
24 1 Shim set
25 1 Shim set
30 1 Retainer 135.5 – 100
31 1 Water pump housing
32 1 Seal kit
33 4 Screw (M6 x 1.0 x 20) 6.8 60.2 –
34 1 Impeller
35 1 Faceplate
36 1 Retaining ring
38 1 O‑ring
39 1 Oil seal
40 1 Oil seal
41 1 Key
42 1 Gasket
43 1 Gasket
44 1 Coupling
45 2 O‑ring

Gear Housing, Propeller Shaft

14
13
10
9 1
8
15
12
5 7
11 6
4
3
2
22 20
21 17
18
19
16
35
34
32
33
27
25
24
31
26 30
29
28
23 67547

Gear Housing, Propeller Shaft

Torque
1 1 Gear housing
2 1 Plug
3 1 Shift crank
4 1 Spool assembly
5 1 Spool
6 1 Cotter pin
7 1 Sleeve
8 1 Forward gear assembly
9 1 Shim set
11 1 Roller bearing cup
12 1 Retaining ring
13 1 Thrust washer
14 1 Tapered roller bearing assembly
16 1 Clutch
17 1 Spring
18 1 Detent pin
20 1 Cross pin
21 1 Reverse gear
22 1 Thrust washer
23 1 Spacer
24 1 Shim set
25 1 Bearing carrier assembly
26 1 Bearing
27 1 Oil seal
28 1 Tapered roller bearing assembly
30 1 Oil seal
31 1 O‑ring
32 1 Screw 6.7 60 –
33 1 Seal
34 1 Tab washer
35 1 Retainer* 285 – 210

* Tighten retainer to 135.5 Nm (100 lb‑ft), then check rolling torque on propeller shaft. If torque is within specification, tighten
retainer to 285 Nm (210 lb‑ft).

Bearings
be replaced.

87 Bearings 92-858064K01
Lubricant
Shims
Seals

95 2-4-C with PTFE 92-802859A 1

Gearcase Removal
! WARNING

b a- Tab washer
f
d- Rear thrust hub
e- Propeller shaft
f- Front thrust hub
d c e
48808
a - Rubber cover
48235

a - Screw
48236
48245
off.


2
3
6 3
1
4
4
5
4
5
5
71422
Torque
2 2 Dowel pin
4 5 Washer
5 5 M12 hex locknut 60 – 44.2
6 1 Screw M12 x 160 30 – 22.1


a - Fill screw
b - Vent screw
a
48252

1. Inspect the propeller shaft for up and down movement, as follows:
a. Position the dial indicator on the propeller shaft, just forward of the splines, as shown in the following illustration.
b. Push the propeller shaft down and zero the dial indicator.
c. Move the propeller shaft up while observing the dial indicator.
d. A shaft deflection of more than 0.08 mm (0.003 in.) indicates a worn propeller shaft bearing.

Dial Indicator Holding Tool 91‑ 89897
2. Check for a bent propeller shaft as follows:
a. Reposition the dial indicator to the threaded end of the propeller shaft. Rotate the propeller shaft while observing the
dial indicator.
b. If the deflection is more than 0.23 mm (0.009 in.), the propeller shaft is bent and should be replaced.
3. Check for propeller shaft end play. There should be no end play. If end play exists, excessive wear has occurred and the
gear housing must be disassembled for inspection.
c
a
b
65183
a - Check propeller shaft deflection

b - Check for bent propeller shaft
c - Check propeller shaft end play


48537


Bearing Carrier Removal, Disassembly, and Assembly

1. Straighten any lock tabs on the tab washer.
NOTE: The drain plug in the bearing carrier must be removed before using the bearing carrier retainer nut wrench to
remove the bearing carrier retainer.
a - Tab
b - Drain plug
b
a
26755

2. Remove the bearing carrier retainer following step a or b, as follows:
IMPORTANT: Drilling into the bearing carrier retainer can potentially damage the gearcase. Ensure that you do not drill
into the gearcase when removing a seized retainer.
a. Remove the bearing carrier retainer by turning the retainer counterclockwise using a bearing carrier retainer nut
wrench.
67569
Bearing carrier retainer nut wrench

b. If the retainer is corroded in place, drill four holes in the retainer and fracture the retainer with a chisel. Pry the
remaining segments out.
a - Drilled holes
27311
c. Remove the tab washer.
3. Pull the bearing carrier from the gear housing by pulling on the outer ring of the bearing carrier. Position the puller jaws
close to the bosses in the carrier.
NOTE: If the bearing carrier is seized in the gear housing, it may be necessary to use heat to loosen the carrier.
a - Puller jaws assembly

b - Puller bolt
a
b
a 67568

Cleaning/Inspection
IMPORTANT: All seals and O‑rings must be replaced as a normal repair procedure to assure effective repair.
1. Clean the bearing carrier with solvent and dry with compressed air.
! WARNING
2. Inspect the bearing carrier for signs of excessive corrosion, especially in the area where the bearing carrier contacts the
gear housing. If excessive corrosion is evident, replace the carrier.
a a - Bearing carrier
b - Inspect for corrosion
26759
b
3. The propeller shaft utilizes a tapered roller bearing and cup for shaft support just forward of the bearing carrier seals. The
reverse gear and bearing assembly must be removed from the bearing carrier to gain access to the propeller shaft tapered
bearing for inspection.
4. Inspect the reverse gear to pinion gear wear pattern. It should be even and smooth. If not, replace the reverse gear, pinion
gear, and forward gear.
5. Check the clutch jaws on the reverse gear for damage. Replace the reverse gear and clutch dog if damage is found on the
clutch jaws.
6. Apply light oil to the reverse gear bearing. Rotate the reverse gear bearing while checking the bearing for rough spots
and/or catches. Push in and pull out on the reverse gear to check for bearing side wear. Replace the bearing if any of the
listed conditions exist.
Disassembly
1. Remove and discard the O‑ring between the bearing carrier and the thrust washer.
IMPORTANT: Clamping the bearing carrier in a vise can damage the carrier. Clamp onto the reinforcing rib only.
2. Place the bearing carrier in a vise. Clamp only on the bearing carrier reinforcing rib.

3. Remove the reverse gear, thrust ring, and bearing as an assembly using a slide hammer puller.
c d e a- Bearing carrier reinforcing rib

b- Bearing carrier
f
c- Slide hammer puller
b d- Reverse gear
e- Thrust ring
f- Bearing (not seen) ‑ located inside carrier
a 26758

4. Inspect the gear to pinion gear contact pattern. It should be even and smooth. If not, replace the gears which shows
abnormal contact wear pattern.
5. Inspect the rear gear for hairline fractures. Replace the rear gear and pinion gear if any fractures are found. If extensive
damage is observed, such as chips, spalling, or broken teeth, replace all of the gears.
6. Check the clutch jaws on the rear gear for damage. Replace the rear gear and clutch dog if damage is found on the clutch
jaws.
a - Rear gear
a b - Clutch jaws
b
63605
7. Remove the thrust washer from the reverse gear assembly.

8. Use a suitable mandrel and universal puller plate to press the bearing from the reverse gear.

b- Bearing
c- Gear
d d- Mandrel
a
b
c
28472

9. Inspect the gear and thrust ring for excessive wear, cracks, or damage. Replace the appropriate components if any of
these conditions are found.
NOTE: Inspect the aft propeller shaft tapered roller bearing for pits, scoring, discoloration, or excessive looseness. Replace
the bearing and bearing race inside of the carrier if these conditions exist.
10. Perform the following step a or b, as necessary.
a. If replacing the seals only: Remove the oil seals with a suitable punch, being careful not to damage the bore of the
bearing carrier. Discard both of the seals.
a - Seals
29360
b. If replacing the tapered roller bearing and seals: Remove the seals with a punch as noted above. There are slots
cast into the carrier to aid in the removal of the bearing race with puller jaws.
b a - Slots
b - Bearing carrier
29393

11. Remove the tapered bearing race from the carrier using a bearing puller assembly, pilot washer, and seal driver guide.
Discard the bearing, race, and both seals.
a
a- Bearing puller assembly
b- Pilot washer
c- Seal driver guide
d- Race
b
c
2972
Bearing Puller Assembly 91‑ 83165T

Assembly
1. Clean all of the components with a suitable solvent and dry the parts thoroughly using compressed air.
2. Lubricate the bore that the tapered bearing race is pressed into with High‑Performance Gear Lubricant.

87 Tapered bearing race bore 92-858064K01
Lubricant
3. Assemble the bearing race onto the driver.
4. Press the bearing race into the bearing carrier until the race bottoms out in the bearing carrier.
a- Seal driver guide

a b- Driver rod
c- Hex nut
d- Bearing cup driver/oil seal installer
b e- Tapered bearing race
c
d
e
29359

5. Thoroughly clean the bore in which the first seal is to be pressed.

6. Assemble the first seal, with the lips of the seal facing away from the driver shoulder, onto the long end of the oil seal
driver.
7. Apply Loctite 380 to the outside diameter of the oil seal.

8. Press on the oil seal driver until the driver bottoms out on the bearing race.
a a- Seal driver guide

b- Driver rod
c- Hex nut
b d- Bearing cup driver/oil seal installer
e- Bearing race
c f- Oil seal (first)
d
e
f
29357

9. Assemble the second seal, with the lips of the seal facing the driver shoulder, onto the short end of the driver seal.
10. Apply Loctite 380 to the outside diameter of the seal.

11. Press on the oil seal with the driver until the driver bottoms out on the bearing race.
a- Seal driver guide

a b- Driver rod
c- Hex nut
b d- Bearing cup driver/oil seal installer
e- Bearing race
c f- Oil seal (second)
d
e
f

12. Lubricate the seal lips and fill the area between the seals with 2‑4‑C with PTFE.

95 2-4-C with PTFE Oil seal lips and between oil seals 92-802859A 1

13. Install the propeller shaft tapered roller bearing into the carrier bearing race.
14. Install the thrust washer and a new ball bearing onto the reverse gear. Press on the inner race of the ball bearing using the
pilot washer until the pilot washer bottoms out on the gear.
a- Pilot washer
a
b- Ball bearing
c- Thrust washer
d- Reverse gear
b c
28473

15. Lubricate the bore that the bearing is pressed into with High‑Performance Gear Lubricant.

87 Bearing bore in carrier 92-858064K01
Lubricant
16. Press the reverse gear assembly into the bearing carrier until the bearing bottoms out in the bearing carrier.
a a- Bearing cup driver

b b- Reverse gear
c- Thrust washer
c d- Ball bearing
d e- Tapered bearing
f- Seal
e g- Seal
f
g
29354

17. Lubricate the O‑ring with 2‑4‑C with PTFE and install the O‑ring onto the bearing carrier.
a
a - O‑ring
b - Bearing carrier
b 28490



2. Slide the V‑ring seal off the driveshaft.
a - V‑ring seal
b - Water tube coupler
b c - Screws (M6 x 20) (2 each side)
a
c 67693

a - Impeller
b - Drive key
a
b
67717

7. Remove the gaskets and water pump faceplate.
a
a - Gaskets
b - Faceplate
b
67719

2. Inspect the faceplate for grooves or rough surfaces.
3. Inspect the stainless steel gasket coated surface for scratches or damage. If the coating is scratched or damaged, replace
the stainless steel gasket.

a
b - Coating
b
46007
4. Replace the fiber gasket.

55952

b a - Impeller
55953
Oil Seal Carrier

Removal
NOTE: Push down on the oil seal carrier to aid in the removal of the retaining ring above the oil seal carrier.
1. While pushing down on the oil seal carrier, use a flat tip screwdriver to aid in the removal of the retaining ring above the oil
seal carrier.

b - Retaining ring
a b
67720
2. Remove the oil seal carrier from the gear housing. It may be necessary to gently pry up on it with two screwdrivers.
NOTE: When prying the oil seal carrier up, avoid contact with the painted surface of the gear housing, or protect the
painted surface where the tools may contact the gear housing. This will prevent paint damage that could result in future
corrosion.
a - Screwdrivers
b - Oil seal carrier
a
67729

Disassembly
Driveshaft Removal, Inspection, Disassembly, and Assembly

Removal
1. Place the driveshaft holding tool onto the driveshaft.
2. Install the pinion nut wrench onto the propeller shaft. It may be necessary to rotate the driveshaft to align the pinion gear
nut into the pinion nut wrench slot.
3. Install the bearing carrier into the gear housing backwards to support the propeller shaft and to keep the pinion nut wrench
aligned.
4. Use the driveshaft holding tool to loosen the pinion nut by rotating the driveshaft counterclockwise.
a - Driveshaft holding tool

a
b - Pinion nut wrench
c - Bearing carrier (installed backwards)
67684
b
5. If the driveshaft is broken, place the propeller shaft adapter onto the propeller shaft splines. Hold the shift shaft in forward
gear and loosen the pinion nut by rotating the propeller shaft counterclockwise to turn the gears, loosening the pinion nut.
a- Shift shaft tool (fabricate from old shift shaft)

b- Pinion nut wrench
c- Bearing carrier (installed backwards)
a d- Propeller shaft adapter
b c 67732

6. Remove the upper driveshaft tapered bearing retainer with the driveshaft bearing retainer wrench.
a - Retainer
b
a
67731

7. Remove the pinion nut by rotating the driveshaft, or the propeller shaft, in a counterclockwise direction.
8. Remove all tools.
9. Remove the driveshaft and all components by pulling the driveshaft straight out of the gear housing, as shown.
67733
IMPORTANT: The pinion bearing rollers are free to fall out of the pinion bearing once the driveshaft is removed. Be careful
not to lose the 18 bearing rollers.
NOTE: If the pinion gear is seized onto the driveshaft, place the gearcase in a vise using soft jaw vise covers. Place a
block of wood on the gear housing mating surface. Use a mallet and carefully tap the gear housing away from the
driveshaft.
IMPORTANT: Striking a gear housing directly with a mallet, or dropping the gear housing, could distort the gear housing
resulting in gear housing failure.
a - Wood block
b - Driveshaft in soft jaw vise
a
b
29158
10. Move the propeller shaft down to retrieve the pinion gear, washer, and nut from inside the gear housing.

11. Remove the lower driveshaft bearing cup and shims with a slide hammer puller. Retain and record the shims for
installation.
a- Shims
c b- Bearing race
c- Slide hammer puller
d- Driveshaft bearing cup
b
a
67734
Inspection
1. Clean all parts with a suitable solvent and dry the parts with compressed air. Do not spin the bearings.
2. The condition of the upper and lower driveshaft bearing cups is an indication of the condition of each of the tapered roller
bearings on the driveshaft. Replace the bearing and bearing cup if the cup is pitted, grooved, scored, worn unevenly,
discolored from overheating, or has embedded particles.
3. Inspect the bearing surface on the driveshaft where the needles of the lower pinion bearing roll. Replace the pinion bearing
and the driveshaft if the shaft is pitted, grooved, scored, worn unevenly, discolored from overheating, or has embedded
particles.
4. Inspect the splines at both ends of the driveshaft for a worn or twisted condition. Replace the driveshaft if either condition
exists.
5. Inspect the driveshaft for grooves where the water pump base oil seals contact the shaft. Replace the driveshaft if grooves
are found.
a b c a
a - Splines
c - Seal surface
46058
6. Inspect the pinion gear for pitting, chipped or broken teeth, hairline fractures, and excessive or uneven wear. Replace the
pinion gear and the forward gear as a set if any defects are found.
Disassembly
NOTE: Do not remove the upper and lower tapered roller bearings from the driveshaft unless replacement is indicated. The
bearings cannot be used after removal.
NOTE: If one driveshaft tapered roller bearing is damaged, both tapered bearings and spacer must be replaced as a set.
1. Both the upper and lower tapered roller bearings can be removed from the driveshaft in one operation. Using the bottom
bearing cup removed from the gear housing, place the cup on top of a vise leaving the vise jaws open enough to allow the
driveshaft to slide through.

2. Place the driveshaft through the cup and vise until the bottom bearing is resting in the cup. While holding the driveshaft, tap
on the top of the shaft with a dead blow hammer until the bearings are free. Do not drop the shaft when performing this
operation.
a - Driveshaft with both upper and lower bearings

b - Lower bearing cup removed from gearcase
b
29453
Assembly
1. Apply High‑Performance Gear Lubricant on the inside diameter of the driveshaft bearings.

87 Inside diameter of the driveshaft tapered bearings 92-858064K01
Lubricant
2. Install the lower tapered roller bearing to the driveshaft, with the small outside diameter of the bearing facing toward the
pinion gear end of the driveshaft.
3. Install a used pinion nut onto the end of the driveshaft. Leave approximately 2 mm (1/16 in.) of nut threads exposed. The
driveshaft threads must not extend beyond the nut or thread damage will result when pressing the bearing on.
4. Press the lower bearing onto the driveshaft with the driveshaft bearing installation tool.
a- Pinion nut
a b- Driveshaft
c- Lower driveshaft tapered bearing
e
47838

5. Install the upper bearing onto the driveshaft, with the large outside diameter of the bearing facing the pinion gear end of the
driveshaft.

a- Pinion nut
b- Driveshaft
b e- Driveshaft bearing installation tool
f- Flat washer (obtain locally)
c
d e
f
47836
Propeller Shaft Assembly and Front Gear Bearing Cup

Removal
1. Tilt the propeller shaft to the starboard side of the gear housing and remove the shaft.
a - Propeller shaft
a 67735
2. Two notches are provided in the gear housing just forward of the front gear bearing cup, to position the puller jaws for
easier removal of the bearing cup and shims.
a - Notches
b - Shims
a c - Front gear bearing cup
b c 28266

3. Remove the front gear bearing cup and shims. Measure and make note of the shim thickness. If shims are not damaged,
they may be reused.
a- Shims
g b- Bearing cup
c- Jaws (from slide hammer puller kit)
h d- Puller head (from slide hammer puller kit)
e- Puller shaft
f- Guide plate
g- Washer
h- Nut
a c d e f
b
29347

Guide Plate 91‑816243
Propeller Shaft Disassembly

NOTE: When accomplishing the next step, all of the parts are free to come apart. Work closely over a workbench to ensure the
parts are not dropped or damaged, and to avoid personal injury.
1. Remove the propeller shaft preload spacer and shims.
2. Remove the spring around the clutch, being careful not to overstretch it during removal. If the spring does not coil back to
its normal position once it has been removed, it must be replaced.
a a - Spring
b c b - Shims
c - Preload spacer
3443
3. Remove the detent pin.

4. Remove the cross pin that goes through the clutch.
5. Remove the remainder of the components.
e a
f a- Detent pin
b- Clutch band (faces toward reverse gear)
b c- Cross pin
d
d- Spool and actuating shaft assembly
e- Front gear assembly
f- Clutch
c
3444

Inspection
1. Clean all the parts with a suitable solvent and dry the parts thoroughly using compressed air, being careful not to spin the
bearings.
2. Inspect the sliding clutch jaws for damage. Jaws must not be chipped or rounded off. Replace the clutch if they are.
3. The propeller shaft utilizes two tapered roller bearing and cup assemblies for propeller shaft support. One tapered bearing
is forward of the bearing carrier seals. The rear gear assembly must be removed from the bearing carrier to gain access to
this bearing for inspection. The other tapered bearing is located inside the front gear assembly. The front gear assembly
must be removed from the propeller shaft to gain access for inspection. A snap ring retainer and flat washer secure this
bearing assembly.
a
a- Snap ring
b b- Flat washer
c- Tapered bearing race
c d- Tapered bearing
e- Front gear bearing
f- Front gear
d
f 29526
NOTE: The front gear bearing should not be removed from the gear unless replacement is necessary. The bearing cannot
be used if the bearing is removed.
4. Inspect the propeller shaft splines at both ends for a broken, worn, or twisted condition. Replace the propeller shaft if any of
these conditions exist.
5. Inspect the surface of the propeller shaft where the bearing carrier seal lips contact the shaft. If the oil seals have made
grooves, replace the propeller shaft and oil seals.
6. Inspect the propeller shaft for a bent condition using V‑blocks and a dial indicator.
a. Position the propeller shaft bearing surfaces on the V‑blocks.
b. Adjust the height of the V‑blocks to level the propeller shaft.
c. Position the dial indicator tip just forward of the propeller shaft splines.
7. Rotate the propeller shaft and observe the dial indicator movement. If the indicator in the dial moves more than 0.23 mm
(0.009 in.), replace the propeller shaft.
a - Check movement with dial indicator here

b b - Seal surface area
a
29505
Front Gear Inspection, Disassembly, Assembly

Inspection
1. Clean the front gear assembly and the front gear bearing cup with a suitable solvent and dry with compressed air. Be
careful not to spin the bearings.
2. Inspect the front gear to pinion gear contact pattern. It should be even and smooth. If not, replace the gears which show
abnormal contact wear pattern.

3. Inspect the front gear for hairline fractures. Replace the front gear and pinion gear if any fractures are found. If extensive
damage is observed, such as chips, spalling, or broken teeth, replace all of the gears.
4. Check the clutch jaws on the front gear for damage. Replace the rear gear and clutch dog if damage is found on the clutch
jaws.
b a - Front gear teeth

b - Clutch jaws
3048
5. Inspect the propeller shaft tapered roller bearing on the inside of the front gear and its respective bearing cup. If either the
bearing or the bearing cup surface is pitted, grooved, scored, worn unevenly, discolored from overheating, or has
embedded particles, replace the tapered roller bearing assembly.
6. Inspect the tapered roller bearing pressed onto the front gear and the bearing cup surface. If either the roller bearing or
bearing cup is pitted, grooved, scored, worn unevenly, discolored from overheating, or has embedded particles, replace the
front gear bearing assembly.
Disassembly
IMPORTANT: Do not remove the pressed on tapered roller bearing from the front gear unless replacement of the bearing is
required. The bearing cannot be used after it has been removed.
1. If inspection determines that replacement of the front gear tapered bearing is required, separate the gear from the bearing
as follows:
a. Install the universal puller plate between the front gear and the tapered bearing.
b. Place the assembly on a press and press the gear out of the bearing with a suitable mandrel.
NOTE: The tapered bearing cup and cone must be replaced as a set.
a - Front gear bearing

a c
c - Mandrel
b 28155

2. If inspection determines that replacement of the propeller shaft tapered roller bearing is required, remove the bearing as
follows:
IMPORTANT: Use suitable eye protection when removing or installing the snap ring.

a. Use snap ring pliers to remove the snap ring. Remove the tapered roller bearing assembly out of the inside of the
front gear.
a
a- Snap ring
b b- Flat washer
c- Tapered bearing cup
c d- Tapered bearing cone
e- Front gear bearing cone
f- Front gear
d
f 29526
Assembly
1. Apply High‑Performance Gear Lubricant to the outside diameter of the front gear bearing surface.

87 Outside diameter of front gear bearing surface 92-858064K01
Lubricant
2. Place the forward gear onto a wood block with the teeth facing the wood block.
3. Install the front gear bearing onto the gear and use a suitable mandrel to press the bearing onto the gear. Press only on
the inner race of the bearing.
a a - Mandrel
b - Wood block
35614
4. Apply High‑Performance Gear Lubricant to the inside diameter of the front gear. Install a new tapered roller bearing cone,
race, and flat washer into the front gear until the bearing seats.
IMPORTANT: Use suitable eye protection when removing or installing the snap ring.

5. Install the snap ring into the groove of the front gear to secure the tapered roller bearing assembly.
a
a- Snap ring
b b- Flat washer
c- Tapered bearing cup
c d- Tapered bearing cone
e- Front gear bearing cone
f- Front gear
d
f 29526

87 Inside diameter of front gear 92-858064K01
Lubricant
Shift Spool Assembly

Inspection
1. Clean the assembly with solvent and dry all parts using compressed air.
2. Inspect the shift spool assembly for damage. Small nicks and burrs may be smoothed. If any parts are damaged or worn
excessively, replace the complete shift spool assembly.
3. Inspect the shift spool for wear in the area where the shift crank comes into contact.
a
b a - Contact area
b - Nonratcheting shift spool
46449
4. Verify the spool spins freely.
5. Verify the spool has end play. The end play may be achieved by turning the castle nut clockwise down until it is snug and
then backing off the nut counterclockwise to the first cotter pin slot.
a - End play
b - Shift spool
b
a 46450
Shift Spool
End play 0.05–0.25 mm (0.002–0.010 in.)
Disassembly
NOTE: If the spool spins freely and has the proper clearance, it will not be necessary to disassemble and reassemble the
spool. If the spool does not function properly, proceed with the following disassembly procedures.
NOTE: Disassembly of the shift spool is for cleaning and inspection of the internal parts due to an improperly functioning shift
spool assembly or debris in the gear housing and/or shift spool assembly. Individual components for the shift spool are not
available as replacement parts. If the shift spool does not function properly and the following cleaning and adjustment
procedures do not correct the problem, replace the shift spool assembly.
1. Remove and discard the cotter pin.

2. Remove the castle nut and spool.
Reassembly
1. Place the shift spool onto the shift spool shaft.
2. Screw the castle nut down until it touches the spool and a slight resistance is felt.
3. Loosen the castle nut until the cotter pin slot of the nut is aligned with the hole in the shaft. If the castle nut is threaded
down and the cotter pin slot is already aligned at the hole in the shift spool shaft, back the castle nut off until the next
available slot in the nut is aligned with the hole in the shaft.
4. Insert a new cotter pin and bend the ends of the cotter pin in opposite directions.
5. Verify the spool has end play. If it does not, adjust the castle nut again.
a- Shift shaft
b- Spool
c- Castle nut
d d- Cotter pin
a b c 29541
Shift Spool
End play 0.05–0.25 mm (0.002–0.010 in.)
6. If this adjustment did not produce the desired results, it will be necessary to disassemble, clean, and reassemble the shift
spool assembly. If the spool assembly has already been disassembled and cleaned, replace the shift spool assembly.
Shift Shaft Removal, Disassembly and Inspection, Assembly

Removal
NOTE: It is possible to remove and service the shift shaft assembly (but not the shift crank inside the gearcase) without
removing any of the internal components of the gear housing.
1. Remove the screws securing the shift shaft cover.
2. Remove the shift shaft and cover assembly by pulling the cover and shift shaft out of the gear housing.
67736
Shift shaft cover screws
3. Remove the shift crank from the inside of the gear housing. Clean it with a suitable solvent and dry it thoroughly. Inspect it
for wear in the areas that contact the shift spool and inspect the splines and the pivot pin for damage or wear.
NOTE: The shift crank has a locating tab. On right‑hand rotation gearcases, the tab faces toward the propeller.
b c
a- Pivot pin
a b- Contact area
c- Splines
d- Locating tab
d
29361


1. Remove the shift shaft from the cover.
2. Clean all components with a suitable solvent and dry thoroughly with compressed air.
3. Inspect all components:
a. Inspect the shift shaft cover for cracking, damage, or excessive wear.
b. Inspect the oil seal inside the cover and the O‑ring on the outside of the cover for damage or excessive wear.
Remove the retaining ring, then remove the seal.
4. Inspect the shift shaft splines and oil seal surface for corrosion or excessive wear. Replace the shift shaft if either of these
b a - Oil seal surface

b - Splines
b
a
29543
Pinion Bearing Removal

NOTE: Inspect the bearing surface on the driveshaft where the rollers of the lower pinion bearing roll. The condition of the
driveshaft at this location gives an indication of the condition of the roller bearing. Replace lower pinion bearing (rollers and
race as a set) if the driveshaft is pitted, grooved, scored, worn unevenly, discolored from overheating, or has embedded
particles.
IMPORTANT: All the roller bearings (18) must be in place inside the bearing race while driving the pinion bearing from the gear
housing. It is recommended that the cardboard tube provided with a new pinion bearing be used to keep the bearings in place
while driving out the old pinion bearing.
IMPORTANT: Do not use the bearing (race or rollers) once it has been removed.
a - Pinion bearing
a
29351
Remove and discard the pinion bearing (race and rollers) using the tools as shown.
a- Pinion bearing
e b- Driver head
c- Pilot washer
d
d- Driver rod
e- Dead blow hammer
67562
a
Driver Head 91‑ 36569T

Driver Rod 91‑ 37323

a
49365
holes.

1. Lubricate the gearcase pinion bearing bore with High‑Performance Gear Lubricant.

87 Pinion bearing bore 92-858064K01
Lubricant
2. Install the pinion bearing onto the mandrel so the letter and number side of the bearing faces up.
IMPORTANT: All 18 roller bearings must be in place when pressing the bearing into the gear housing.
3. Insert the mandrel and bearing into the gearcase pinion bearing bore.
4. Install the puller plate onto the puller rod and insert the puller rod into the gearcase driveshaft bore. Thread the puller rod
into the mandrel.

5. Secure the puller rod and tighten the nut until the mandrel contacts the gearcase.
a- Puller rod
b- Puller plate
a c- Pilot
d- Pinion bearing
f e- Mandrel
b f- Hex nut
e
67563
Front Gear Bearing Cup Installation

NOTE: If the front gear, bearing and cup, or gear housing were not replaced, install the same measurement of shims that were
removed. If the front gear, bearing and cup, or gear housing were replaced, install 0.762 mm (0.030 in.) shims.
1. Lubricate the front gear bearing cup bore with High‑Performance Gear Lubricant.

87 Front gear bearing cup bore 92-858064K01
Lubricant
2. Install the shims into the front gear bearing cup bore.
IMPORTANT: Verify the bearing cup is positioned as straight as possible to avoid damaging the bore while pressing the
bearing cup in.
f a- Shims
b- Front gear bearing cup
c- Bearing cup driver
d- Propeller shaft (old
nonserviceable)
e - Propeller shaft holder
f - Mallet
a b c d e 63779

Driveshaft Bearing Rolling Torque and Pinion Gear Height

IMPORTANT: The sequence of setting up the driveshaft bearing rolling torque and pinion height must be completed before
checking the front and rear gear backlash. Failure to set the driveshaft bearing rolling torque and pinion height prior to checking
the forward and reverse gear backlash may cause errors in determining the correct lash, and will increase assembly time of the
gear housing to factory specifications.

Driveshaft and Pinion Gear Installation

NOTE: If the original shims were not retained, or if the pinion gear, driveshaft, driveshaft upper tapered roller bearing and cup,
or gear housing were replaced, start by installing a 5.08 mm (0.020 in.) shim for the lower tapered roller bearing and 2.54 mm
(0.010 in.) shim for the upper tapered roller bearing.
NOTE: If the original shims were retained or the measurement is known, and none of the above listed parts were replaced,
install the same shims or same amount of shims.
IMPORTANT: Do not apply Loctite 271 Threadlocker to the threads of the pinion gear nut until after the pinion height, pinion
bearing rolling torque, and the front gear lash is confirmed.
1. Place the lower tapered bearing shims into the driveshaft housing bore.
2. Install the lower tapered bearing cup into the driveshaft housing bore.
a - Tapered bearing cup

b - Shims
57838
3. Install the front gear assembly—not assembled onto the propeller shaft.
IMPORTANT: The front gear must be installed to support the pinion nut wrench.
4. Install the pinion gear and driveshaft.
5. Secure the pinion gear with the washer and pinion nut.
NOTE: Install the pinion gear nut with the flat side of the nut away from the pinion gear.
6. Install the upper driveshaft tapered roller bearing shim.
7. Install the upper driveshaft tapered roller bearing cup. Apply 2‑4‑C with PTFE to the driveshaft bearing retainer threads and
install the retainer.

95 2-4-C with PTFE Retainer threads 92-802859A 1
8. Tighten the driveshaft bearing retainer to the specified torque with the driveshaft bearing retainer wrench.
a - Retainer
b
a
67731

Driveshaft bearing retainer 135.5 – 100
9. Install the driveshaft holding tool.

10. Install the propeller shaft into the front gear.

11. Install the pinion nut wrench over the propeller shaft and secure the pinion nut with the pinion nut wrench.
12. Install the propeller shaft holder.
13. Use the driveshaft holding tool to tighten the pinion nut to the specified torque.
a a - Driveshaft holding tool

b - Propeller shaft holder
c - Pinion nut wrench
66166
c


14. Remove the driveshaft holding tool, propeller shaft holding tool, pinion nut wrench, and propeller shaft.
Driveshaft Bearing Rolling Torque

1. Install the driveshaft holding tool.

2. Use the driveshaft holding tool to check the driveshaft bearing rolling torque. Units correctly assembled to this point would
show a rolling torque of 0.45–1.13 Nm (4–10 lb‑in.). If the rolling torque is not within specification, the shim under the upper
tapered roller bearing cup will need to be changed and the rolling torque rechecked. If the rolling torque is too high, add
shims under the upper bearing cup. If the rolling torque is too low, remove shims from under the upper bearing cup.
NOTE: Preload will change approximately 0.056 Nm (0.5 lb‑in.) of rolling torque per 0.025 mm (0.001 in.) of shim change.

Checking and Adjusting Pinion Gear Height with Pinion Gear Locating Tool 8M0089163
a- Arbor
b- Socket head cap screws
f c- Retaining ring
e g
d- Pinion gauge adapter tool
e- Retaining ring with screw
f- Gauging block
d g- Locating discs (1–5)
h- O‑ring (located inside of the pinion gauge
adapter tool)
B A a
b h
c
56326
IMPORTANT: The forward gear assembly must be installed when using pinion gear locating tool 8M0089163.
1. Install the retaining ring onto the first groove on the arbor.
2. Use disc #2 and the gauging block flat #4 and install the pinion gear locating tool into the gearcase.
f a- Feeler gauge
a
b- Pinion gear locating tool
c- Disc #2
d- Flat #4
e e- 0.635 mm (0.025 in.)
f- Pinion gear
c b
c d 66168

3. Insert the thickest feeler gauge that fits snug between one tooth of the pinion gear and the shimming tool. Record the
measurement.
4. Rotate the driveshaft 120 degrees in a clockwise direction and check the clearance. Record the measurement.
5. Repeat this process until three readings have been taken.
6. Add the three measurements together and divide the sum by three to get the average pinion gear height. Make note of this
average measurement.
Pinion Gear
Height 0.635 mm (0.025 in.)
7. If the average pinion gear height is not correct, add or subtract shims beneath the lower and upper driveshaft tapered
bearing race.
IMPORTANT: Add or subtract shims beneath the lower and upper driveshaft bearing races proportionally to maintain the
driveshaft bearing rolling torque.
Example 1 (if pinion height is too high)

Pinion clearance: 1.02 mm (0.040 in.)
Pinion clearance specification (subtract): 0.635 mm (0.025 in.)
Remove this quantity of shims: 0.381 mm (0.015 in.)
Provides backlash of: 0.635 mm (0.025 in.)

Example 1 (if pinion height is too low)

Pinion clearance specification 0.635 mm (0.025 in.)
Pinion clearance (subtract): 0.101 mm (0.004 in.)
Add this quantity of shims: 0.534 mm (0.021 in.)
8. Install the components and tighten the driveshaft bearing retainer to the specified torque.

9. Rotate the driveshaft a minimum of three full turns in a clockwise direction. Check the pinion gear height. If pinion height is
not within specification, adjust the shim thickness and check the pinion clearance. Repeat this process until the average
pinion height is within specification.
10. Verify the driveshaft rolling torque is within specification.
11. Remove the pinion gear locating tool, driveshaft, pinion gear, and front gear.

NOTE: The shift crank has a locating tab. On right‑hand rotation gearcases, the tab faces toward the propeller.
a - Right‑hand rotation top view ‑ tab toward propeller

a b - Right‑hand rotation aft view ‑ shift crank toward starboard
67737
1. Place the shift crank into the pivot pin hole in the forward section of the gear housing. Ensure that the shift crank faces
toward the starboard side of the gear housing for right‑hand rotation gearcases.
Right-hand rotation shown

a - Shift crank
b - Pivot pin
a c - Front gear bearing cup
b c
53487
2. Press the shift shaft seal into the cover and secure with the retaining ring.
3. Install the O‑ring onto the cover.

4. Lubricate the O‑ring and shift shaft seal lips with 2‑4‑C with PTFE.
a a- Retainer
b- Seal
b c- Shift shaft cover
d- O‑ring
d
67738

95 2-4-C with PTFE Shift shaft cover O-ring and shift shaft seal lips 92-802859A 1
5. Install the shift shaft into the gear housing with the swedged end toward the cover. Engage the splined end of the shift
shaft with the shift crank.
6. Install the gasket onto the gear housing.
7. Install the shift shaft cover assembly.
8. Secure the shift shaft cover with four screws. Tighten the screws to the specified torque.
67736
Shift shaft cover screws

Shift shaft cover screws (M6 x 20) 6.8 60.2 –

1. Install the sliding clutch (with band on clutch facing aft) onto the propeller shaft. Align the cross pin holes in the clutch with
the slot in the propeller shaft.
2. Assemble the front gear assembly to the propeller shaft.
3. Assemble the shift spool assembly to the propeller shaft, making sure the cross pin hole of the shift spool shaft is aligned
with the clutch.
4. Assemble the cross pin through the sliding clutch, through the propeller shaft, and through the shift spool shaft hole.

5. Install the detent pin into the third hole in the clutch.
e a
f a- Detent pin
b- Clutch band (faces aft)
b c- Cross pin
d
d- Shift spool and actuating shaft assembly
f- Clutch
c
3444
6. Assemble the cross pin retaining spring over the propeller end of the propeller shaft and wind it around the clutch over the
cross pin hole. Be careful not to distort the spring while assembling it.
IMPORTANT: Verify the spring is wound on so that it does not cross over on itself and that it lies flat against the clutch
once it is assembled. If it does not lie flat against the clutch, a new spring must be installed.
a a- Propeller shaft
b c e b- Cross pin retaining spring
d c- Cross pin (hidden)
d- Sliding clutch
g f f- Spool and actuating shaft assembly
g- Detent pin (hidden)
29542
Propeller Shaft Installation

NOTE: The shift/clutch assembly should be in the neutral detent position when installing the propeller shaft.
1. To allow for the engagement of the shift spool with the shift crank, tilt the propeller end of the propeller shaft assembly to
the right (starboard) side of the gear housing and hold the shift shaft in neutral while installing the shaft.
67565
Installing propeller shaft
2. Operate the shift shaft to ensure it has been properly installed. The sliding clutch should move forward when the shift shaft
is turned counterclockwise, and should move aft when the shift shaft is turned clockwise.

Driveshaft and Pinion Gear Installation

IMPORTANT: Do not apply Loctite 271 Threadlocker to the threads of the pinion gear nut until after the pinion height, pinion
bearing rolling torque, and the front gear lash is confirmed.
1. Place the pinion gear nut into the pinion nut wrench with the flat side of the nut toward the pinion nut wrench.
2. Install the pinion nut washer onto the pinion nut.
NOTE: For ease of installation, glue the washer to the pinion gear with 3M Adhesive, Bellows Adhesive, or equivalent.

27 Bellows Adhesive Pinion washer 92-86166Q1
3. Insert the pinion gear into the gear housing.
4. With the propeller shaft horizontal, insert the pinion nut wrench with the nut into the gear housing.
5. Insert the driveshaft into the gear housing driveshaft bore. It may be necessary to rotate the driveshaft to engage the
driveshaft splines into the pinion gear splines.
6. Start the pinion nut onto the driveshaft threads by rotating the driveshaft until the nut is snug.
7. Lubricate the driveshaft bearing retainer threads with 2‑4‑C with PTFE and install the retainer.

95 2-4-C with PTFE Driveshaft bearing retainer threads 92-802859A 1
8. Tighten the driveshaft bearing retainer to the specified torque with the driveshaft bearing retainer wrench.
a - Retainer
b
29353

9. Install the bearing carrier into the gear housing backwards to hold the propeller shaft and the pinion nut wrench in position.

10. Tighten the pinion nut to the specified torque by turning the driveshaft with the driveshaft holding tool and torque wrench.
a - Driveshaft holding tool

a
b - Pinion nut wrench
c - Bearing carrier (installed backwards)
67566
b

11. Remove all the tools.
Front Gear Backlash (Forward)

IMPORTANT: Backlash values are only valid if the pinion height is within specification.
1. Install the propeller shaft preload spacer onto the propeller shaft.
NOTE: Do not install the propeller shaft preload shims; they will be installed when checking the propeller shaft preload
bearing, following.
2. Place the bearing carrier assembly into the gear housing being careful to align the rear propeller shaft bearing with the
propeller shaft. It may be necessary to turn the driveshaft to align the teeth of the pinion and reverse gears.
3. Lubricate the bearing carrier retainer nut threads with 2‑4‑C with PTFE. Install the locking tab washer and retainer nut into
the gear housing. Use the bearing carrier retainer nut wrench to tighten the retainer nut hand‑tight.
a - Bearing carrier assembly

b - Propeller shaft bearing
c - Preload spacer
c 67567

95 2-4-C with PTFE Bearing carrier retainer nut threads 92-802859A 1

4. Apply forward pressure to propeller shaft as follows:

a. Attach the puller jaws assembly onto the bearing carrier bosses and propeller shaft.
b. Tighten the puller bolt to the specified torque. Rotate driveshaft three full turns clockwise and tighten the puller bolt to
a - Puller jaws assembly

b - Puller bolt
a
b
a 67568

Puller bolt 5.6 50 –
5. Install a dial indicator and align the dial indicator pointer so that it is perpendicular to and touching the 1 mark on the dial
indicator tool. Tighten the indicator tool onto the driveshaft and rotate the driveshaft so that the needle makes two complete
revolutions. Align the 0 with the dial indicator pointer.
e f a- Nuts (4) (obtain locally)

d b- Threaded rod ‑ 9.5 mm (3/8 in.) (obtain locally)
d- Dial indicator
e- Indicator pointer
f- Backlash indicator rod
a c
a
67739

6. Lightly turn the driveshaft back and forth. This is the amount of backlash. No movement should be noticed at the propeller
shaft. Record the amount of backlash.
7. Loosen the indicator tool and rotate the driveshaft 120° clockwise.
8. Align the pointer so it is perpendicular to the 1 mark on the backlash indicator tool. Tighten the indicator tool onto the
driveshaft and rotate the driveshaft so the dial indicator needle makes two complete revolutions. Align the 0 with the dial
indicator pointer.
9. Lightly turn the driveshaft back and forth. No movement should be noticed at the propeller shaft. Record the amount of
backlash. Repeat this process for a total of three backlash measurements.
10. Add the three measurements and divide by three, this is your average backlash measurement.
11. If the backlash is less than the specified minimum, remove the shims from behind the front gear bearing race to obtain the
correct backlash.

12. If the backlash is more than the specified maximum, add shims behind the front gear bearing race to obtain the correct
backlash.
NOTE: By adding or subtracting 0.025 mm (0.001 in.) shim, the backlash will change approximately 0.025 mm (0.001 in.).
Front Gear
Backlash 0.482–0.660 mm (0.019–0.026 in.)
13. If the backlash is more than the specified maximum, add shims behind the front gear bearing race to obtain the correct
backlash.
Example 1 (if backlash is too high)

Front gear backlash measurement: 1.02 mm (0.040 in.)
Specification average (subtract): 0.56 mm (0.022 in.)
Add this quantity of shims: 0.46 mm (0.018 in.)
14. If the backlash is less than the specified minimum, remove the shims from behind the front gear bearing race to obtain the
correct backlash.
Example 2 (if backlash is too low)

Specification average: 0.56 mm (0.022 in.)
Front gear backlash measurement (subtract): 0.28 mm (0.011 in.)
Subtract this quantity of shims: 0.28 mm (0.011 in.)
15. When the front gear backlash is within the specification range, apply Loctite 271 Threadlocker to the threads of a new
pinion nut. Install the pinion nut and tighten to the specified torque.

7 Loctite 271 Threadlocker Pinion nut threads 92-809819

Rear Gear Backlash

Although reverse gear backlash is not adjustable, it may be checked as follows:
NOTE: The propeller shaft shims must be removed from the propeller shaft to check the rear gear backlash.
1. Tighten the bearing carrier retainer nut to the specified torque.

First 135.5 – 100
Second 285 – 210
NOTE: Tighten the retainer to 135.5 Nm (100 lb‑ft). Rotate the propeller shaft several revolutions, then tighten the retainer
to 285 Nm (210 lb‑ft).
2. Apply backward pressure on the propeller shaft by holding the shift crank against the rear gear.

3. Install a dial indicator and align the dial indicator pointer so that it is perpendicular to and touching the 1 mark on the dial
indicator tool. Tighten the indicator tool onto the driveshaft and rotate the driveshaft so that the needle makes two complete
revolutions. Align the 0 with the dial indicator pointer.
e f a- Nuts (4) (obtain locally)

d b- Threaded rod ‑ 9.5 mm (3/8 in.) (obtain locally)
d- Dial indicator
e- Indicator pointer
f- Backlash indicator tool
a c
a
67739

4. Lightly turn the driveshaft back and forth. This is the amount of backlash. No movement should be noticed at the propeller
shaft. Record the amount of backlash.
5. Loosen the indicator tool and rotate the driveshaft 120° clockwise.
6. Align the pointer so it is perpendicular to the 1 mark on the backlash indicator tool. Tighten the indicator tool onto the
driveshaft and rotate the driveshaft so the dial indicator needle makes two complete revolutions. Align the 0 with the dial
indicator pointer.
7. Lightly turn the driveshaft back and forth. No movement should be noticed at the propeller shaft. Record the amount of
backlash. Repeat this for a total of three backlash measurements.
8. Add the three measurements together and divide the sum by three. This is your average rear gear backlash. If the rear
gear backlash is not within specification, the gear housing is not properly assembled or the parts are excessively worn and
must be replaced.
Rear Gear Backlash Specification

Right‑hand rotation 1.27–1.47 mm (0.050–0.058 in.)
9. Remove all of the backlash indicator tools and mounting hardware.

IMPORTANT: Install a maximum of two shims on the propeller shaft to obtain the specified propeller shaft rolling torque. To
obtain the specified rolling torque, shims of different thicknesses may have to be interchanged. Do not use a shim thinner than
0.51 mm (0.020 in.).
2. Install the thrust spacer onto the propeller shaft.
3. Install a shim onto the propeller shaft. Do not use a shim thinner than 0.51 mm (0.020 in.). A maximum of two shims may
be installed on the shaft to obtain the specified rolling torque. If two shims are required, install the thinner shim last.
d
a b c a- Thin shim if required (install onto propeller shaft last)
b- Shim
c- Thrust spacer
d- Propeller shaft
65248
driveshaft to align the teeth of the pinion with the rear gear.

5. Insert the small rectangular tab of the new tab washer into its corresponding slot in the gearcase at the 12 o'clock position
fill/drain hole in the bearing carrier.
b a - Tab washer
b - Rectangular tab
c - U‑shaped tab
a
c 29392
6. With the gear housing in neutral, install the bearing carrier retainer nut.
7. Use the bearing carrier retainer nut wrench to tighten the retainer nut to the first specified torque.
9. Use the bearing carrier retainer nut wrench to tighten the retainer nut to the final specified torque.
a b c d
65266
a- Install bearing carrier retainer nut

b- Tighten to first specified torque
c- Rotate propeller shaft
d- Tighten to final specified torque

First 135.5 – 100
Final 285 – 210
10. Remove the bearing carrier retainer nut wrench from the propeller shaft.

11. Install the propeller shaft adapter. Use a torque wrench to rotate the propeller shaft in the direction of normal rotation with a
slow steady motion.
b a - Torque wrench
a b - Propeller shaft adapter
65317


NOTE: Preload will change approximately 0.056 Nm (0.5 lb‑in.) of rolling torque per 0.025 mm (0.001 in.) of shim change.
13. If the rolling torque is too high, install a thinner shim on the propeller shaft, aft of the thrust spacer. If the torque is too low,
install a thicker shim. Be certain the shims are installed aft of the thrust spacer.
IMPORTANT: Install a maximum of two shims on the propeller shaft to obtain the specified propeller shaft rolling torque.
To obtain the specified rolling torque, shims of different thicknesses may have to be interchanged. Do not use a shim
smaller than 0.51 mm (0.020 in.).
NOTE: If the shims are changed, tighten the bearing carrier retainer nut to the first specified torque. Rotate the propeller
shaft several times to seat the propeller shaft tapered bearing. Tighten the retainer nut to the second specified torque. Use
the torque wrench to check the rolling torque. Repeat this procedure each time the shims are changed.

First 135.5 – 100
Final 285 – 210
Bearing Carrier Final Installation

1. Remove the bearing carrier and lubricate the following as specified:
a. Lubricate the carrier O‑ring with 2‑4‑C with PTFE.
b. Lubricate both the forward and aft outside diameters of the bearing carrier and gearcase area where the carrier will
seat with 2‑4‑C with PTFE.

c. Fill the space between the carrier oil seals with 2‑4‑C with PTFE.
a - Bearing carrier
b - Propeller shaft bearing
c - Preload spacer
c 67567

Carrier O-ring, forward and aft outside diameters of bearing
95 2-4-C with PTFE carrier, gearcase area where carrier will seat, and space 92-802859A 1
between carrier oil seals
2. Place the bearing carrier assembly into the gear housing, being careful to align the rear propeller shaft bearing. It may be
necessary to turn the driveshaft to align the teeth of the pinion and the reverse gears.
3. The lubricant fill screw in the bearing carrier should be located at the 6 o'clock position.
4. Install the antirotation pin.
NOTE: Early model gearcases and bearing carriers do not use an antirotation pin.
a
a - Antirotation pin
b - Bearing carrier installed
b
63817
b a - Tab washer
b - Rectangular tab
c - U‑shaped tab
a
c 29392
6. Fill the bearing carrier retainer nut threads and corresponding gear housing threads with 2‑4‑C with PTFE. Start the
retainer nut into the gear housing threads.

Bearing carrier retainer nut threads and corresponding gear
95 2-4-C with PTFE 92-802859A 1
housing threads

7. Tighten the retainer nut to the first specified torque. Rotate the propeller shaft several times to seat the tapered roller
bearings. Tighten the retainer nut to the final specified torque.

First 135.5 – 100
Final 285 – 210
8. If one tab does not align up in space between two of the notches, continue to tighten retainer until alignment is achieved.
Do not loosen retainer to achieve alignment.
67569
Bearing carrier retainer nut wrench

9. Bend one tab out into a space between two of the notches of the retainer. Bend all the remaining tabs in.
Oil Seal Carrier Installation

NOTE: The oil seal carrier may be lightly tapped into position by sliding the driveshaft bearing retainer wrench over the
driveshaft.
1. Lubricate the oil seal carrier oil seal lips, space between the seals, and the O‑ring with 2‑4‑C with PTFE. Install the oil seal
carrier over the driveshaft and into the gearcase.
b a - O‑ring
b - Oil seal lips
26751
a

Oil seal carrier oil seal lips, space between oil seals, and O-
95 2-4-C with PTFE 92-802859A 1
ring

2. Install the retaining ring above the oil seal carrier.

b - Retaining ring
a b
67720
Water Pump Installation

1. Install the water pump base gasket.
2. Install the water pump faceplate.
3. Install the water pump cover gasket.
a
a - Gaskets
b - Faceplate
b
67719
4. Place a small amount of 2‑4‑C with PTFE on the flat surface of the driveshaft key and install the key onto the driveshaft.
5. Assemble the water pump impeller onto the driveshaft and down over the key.
a - Impeller
b - Drive key
a
b
67717


95 2-4-C with PTFE Flat surface of the driveshaft key 92-802859A 1
6. Apply 2‑4‑C with PTFE to the inside of the pump cover. Rotate the driveshaft in a clockwise direction while pushing down
on the water pump cover.

7. Install the water pump cover screws. Tighten the screws to the specified torque following the sequence shown.
2 3
a - Water pump cover screws
(4)
4 1
a 67740

Water pump cover screws (4) 6.8 60.2 –
IMPORTANT: If the seal installed above the pump housing is not at the proper height, air will be drawn into the pump
resulting in overheating of the engine.
8. Use the tool provided with the seal kit or water pump kit to install the V‑ring seal to the correct height. Push the tool down
over the driveshaft until the tool seats against the pump housing. Do not grease the driveshaft.
a
a - Tool
b - V‑ring seal
b
67741
NOTE: If the tool is not available, lightly press the seal against the housing until specified height is obtained.
Water Pump Cover

Seal height 8.9 mm ± 0.76 mm 0.350 in. ± 0.030 in.)


48537


Checking Gearcase Operation

Prior to filling the gearcase with lubricant, check the gearcase for proper shift operation, as follows:
1. Rotate the shift shaft counterclockwise to the forward gear position. The propeller shaft should rotate clockwise and then
lock (no ratcheting motion).
2. Rotate the shift shaft to the neutral position. The propeller shaft should rotate freely both clockwise and counterclockwise.
3. Rotate the shift shaft clockwise to the reverse gear position. The propeller shaft should rotate counterclockwise and then
lock (no ratcheting motion).
IMPORTANT: If the shifting operation is not as described, the gear housing must be disassembled and the cause
corrected.
Gear Housing Installation

55958

NOTICE
6. Shift the gear housing into forward gear and place the shift block into the forward gear position.

a
48526

splines.
48245

48236
b. Rotate the flywheel clockwise: the propeller shaft should rotate clockwise.
f. Rotate the flywheel clockwise and the propeller shaft should rotate counterclockwise.
a - Rubber cover
48235

Locknuts (M12 x 1.75) (4) 60 – 44.2
Screw (M12 x 35) 75 – 55.3
Anode screw (0.437‑14 x 1.75) 54 – 39.8



a - Fill screw
b - Vent screw
a
48252

Lubricant


Throttle Linkage

Section 7A - Throttle Linkage
Table of Contents
Integrated Air Fuel Module Components........................... 7A-4 Throttle Link Installation..................................................... 7A-7
Throttle Link Removal ....................................................... 7A-6
7
A

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

Throttle Linkage
Notes:

Throttle Linkage

1
3
4
8
6
7
10
11
25
24 1
14
13
18 22
19
12 17 5
20 23
15 16
22
18 21
19
17
48370

Throttle Linkage

Torque
1 6 Screw (M6 x 20) 8 70.8 –
2 1 Throttle body assembly
3 1 Sensor
4 2 Screw (M4 x 16) 2.3 20.3 –
5 1 Intake manifold
6 4 Seal
7 1 Seal
8 1 Link rod
9 1 Socket
10 4 Retainer
11 11 Screw (M6 x 40) 10 88.5 –
12 1 Screw (M4 x 16) 6 53.1 –
13 1 Bracket
14 1 Manifold absolute pressure sensor
15 1 Plastic screw
16 1 Clip
17 2 Shoulder screw 10 88.5 –
18 2 Washer
19 2 Wave washer
20 1 Throttle lever
21 1 Return spring
22 2 Washer
23 1 Throttle link actuator
24 1 Link rod retainer
25 1 Idle air control

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
2. Disconnect the throttle link from the throttle body lever.
48203
3. Remove the screw securing the throttle link actuator to the intake manifold.

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.
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.

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
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 –

Throttle Linkage
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.
14. 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.
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
16. Apply Loctite 242 Threadlocker to the threads of the shoulder screw.

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

Shoulder screw 10 88.5 –

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

Shift Linkage

Shift link pin
95 2-4-C with PTFE Cantilever actuator 92-802859A 1
Bronze bushing

Shift Linkage
Notes:

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
18
48368

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 Bronze bushing
17 1 Cantilever actuator
18 1 Shift detent assembly

Shift Linkage
Shift Bracket Removal

1. Remove the lower starboard cowl. Refer to Section 5A ‑ 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

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

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

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

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

Locknut 6 53.1 –
4. Connect the engine harness connector to the shift position sensor.

5. Secure the 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 5A ‑ Lower Cowl.

Cowl Latch

Section 7C - Cowl Latch
Table of Contents
Rear Cowl Latch Removal................................................. 7C-2 Rear Cowl Latch Installation.............................................. 7C-3
7
C

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.

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
5. Install the latch handle onto the link rod.

Cowl Latch
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

Color Diagrams
Color Diagrams
Section 8A - Color Diagrams
Table of Contents
150 FourStroke EFI Engine Harness................................. 8A-4 150 FourStroke Fuel Flow Diagram................................... 8A-6
150 FourStroke Water Flow Diagram................................ 8A-5 150 FourStroke Oil Flow Diagram......................................8A-7
8
A

Color Diagrams
Notes:

Color Diagrams
Notes:

Color Diagrams
150 FourStroke EFI Engine Harness
1- Engine control module (ECM)

2- Idle air control (IAC) valve
3- Throttle position sensor (TPS)
4- 12‑volt power
5- Alternator
6- Shift position sensor
7- Fuel injector #1
8- Fuel injector #2
9- Fuel injector #3
10 - Fuel injector #4
11 - Start relay
12 - Block pressure sensor
13 - Ignition coil #1 and #4
14 - Ignition coil #2 and #3
15 - 12‑volt power
16 - To starter motor
17 - 12‑volt power to starter
18 - Starter to 12‑volt power
19 - Starter ground
20 - Trim down relay
21 - Trim up relay
22 - To trim pump motor down
23 - To trim pump motor up
24 - Trim to engine ground
25 - Ground
26 - Ground
27 - Analog trim position sensor
28 - Accessory power
29 - SmartCraft boat sensor harness connector (optional accessory)
30 - Remote control
31 - Manifold absolute pressure (MAP) sensor
32 - Fuse block
• A–B: 20‑amp mini fuse ‑ fuel delivery
• C–D: 20‑amp mini fuse ‑ ignition system
• E–F: 15‑amp mini fuse ‑ 14‑pin remote control harness/cowl trim switch
• G–H: 2‑amp mini fuse ‑ vessel accessory harness
33 - Crankshaft position sensor (CPS)
34 - Main power relay
35 - CAN terminator
36 - Block coolant temperature sensor
37 - Cowl trim switch
38 - Oil pressure sensor
39 - Fuel supply module (FSM) pump
40 - Digital trim
41 - Vessel accessory harness
42 - Pitot sensor
43 - Manifold air temperature (MAT) sensor

2 3 6 11 12
4 5 7 8 9 10
150 FourStroke EFI Engine Harness 13 14
16 17 18
15
RED BLK
2 1
B A A B
RED/BLU
WHT/LT BLU
YEL/RED
C BA A B C BA 2 1 2 1 2 1 2 1 86 30 85 87 2 1 3
RED
BLK
GRN
GRN/RED
RED/YEL
RED/YEL
RED
BLK/ORN
PPL/YEL
RED
RED
RED/WHT
BLU/YEL
PPL/YEL
BLK/ORN
RED/BLU
BRN/PNK
RED/BLU
RED/PNK
RED/BLU
ORN/PNK
RED/BLU
YEL/PNK
BLK/BLU
RED
RED/BLU
YEL/RED
PPL/YEL
BLK/ORN
WHT/GRN
LT BLU/WHT
RED
RED
RED
1
2 BLK/WHT
3 WHT/LT BLU
RED
RED
RED
4 GRA
5
6 BLK 19
7 TAN/PPL
8 YEL/PPL
30
9 GRN
10 BLK/GRN S106 BLK
20
858687
11 GRN/WHT
12 LT BLU BLK
13 WHT RED
14 RED
15 GRA/DK BLU S104
16
86
17 BLK/WHT
18 YEL/RED BLK
S105
21
873085
19 RED
20 TAN DK BLU
1 21
22
TAN/BLK
YEL
LT BLU/WHT
23 WHT
24
25
DK BLU GRN 22
26
27
DK BLU
23
28 DK BLU/WHT
29 WHT/DK BLU
30 LT BLU/WHT
31
32 GRN
33 GRN/RED S121
34 PPL/YEL
35 WHT/GRN
36 WHT/ORN
37
38 TAN/ORN
39 BLK
40
41
PNK/BLK
BLK/YEL
BLK
BLK
24
42 BLK/ORN
43 BLK/BLU BLK
YEL/WHT
44
45 BLK 25
46
47
48 YEL/PNK BLK
49 BRN/PNK BLK
BLK
26
50 RED/PNK
51 PPL/BLK
52 PPL
53
54
LT BLU/WHT
BLU/YEL
BRN/WHT 27
55 PPL
56 28
57 RED/BLU
58 RED/BLU
DCEF A B
59 GRA/DK BLU
TAN/PPL
60 TAN/ORN
61
62
PNK/BLK 29
BLK/GRN
63 TAN/LT BLU PPL/BLK
64
65 ORN/PNK
66
67 RED/PPL
68 BLK S102
69 RED/BLK
P NM L K J HG F E D C B A
70 BLK
YEL/RED
GRA
TAN/LT BLU
BRN/WHT
GRN/WHT
LT BLU/WHT
DK BLU 30
WHT
S107
BLK/YEL
RELAY KEY PPL
S103 S109 S101 BLK
RED/PPL
DK BLU/WHT
WHT/DK BLU
LT BLU/WHT
GRN/WHT
WHT/ORN
RED/ORN
YEL/WHT
BLK/GRN
BLK/ORN
BLK/ORN
RED/WHT
RED/PPL
RED/BLU
RED/PPL
BLK/ORN
RED/BLK
BLK/GRN
TAN/BLK
PPL/BLK
PPL/YEL
RED/PPL
PPL/BLK
YEL/PPL
DK BLU
87 87
LT BLU
RED/WHT
RED/WHT
RED/ORN
RED/BLU
RED/YEL
RED/PPL
BLK/ORN
PPL/YEL
WHT
WHT
RED
S108
BLK
PPL
TAN
BLK
RED
85 87a 86
RED
RED
87a
YEL
86 85
30 B A 3 1 2 DCBA BAC B A 3 1 2 1 2 3 B A EG HJ K F A BC D 2 1
30 C B A
30 8685 87 CDEG F HA B
Relay Connector
Relay Components
as Viewed Separated
33
39 36
Page 8A-4.1 43 41 32 31
42 40 38 37 35 34
90-8M0168224 68393
150 FourStroke Water Flow Diagram
e d
r c
b
f
i
m
q o
l j
p
s
g
n
h
Page 8A-5.1
t
90-8M0168224 68390
Color Diagrams
150 FourStroke Water Flow Diagram
a- Water intake
b- Water pump
c- Exhaust tube
d- Water strainer
e- Exhaust manifold
f- Cylinder head
g- Engine block
h- Thermostat housing
i- Water pump indicator fitting with strainer
j- Oil cooler
k- Head gasket bypass
l- Thermostat discharge hose
m- Water pump indicator discharge
n- Fuel supply module
o- Sprayer (located in the driveshaft housing)
p- Through the propeller discharge
q- Water to block (engine running)
r- Block drain (engine not running)
s- FSM cooling water supply hose
t- Flush hose fitting—one‑way check valve

Color Diagrams
150 FourStroke Fuel Flow Diagram
a- Fuel inlet from vessel

b- Low‑pressure fuel filter (20 microns)
c- Fuel supply module
d- Fuel lift pump
e- Recirculation check valve
f- Fuel cooler
g- Fuel pressure regulator
h- Fuel pick‑up tube
i- High‑pressure fuel pump
j- High‑pressure fuel
k- High‑pressure fuel hose
l- In‑line fuel filter (located inside the fuel rail)—design 2
m- In‑line fuel filter—design 1
n- Fuel rail and injectors

150 FourStroke Fuel Flow Diagram
k
n l
g e
j
f
a
Page 8A-6.1
90-8M0168224 68389
150 FourStroke Oil Flow Diagram
g h
I m
Ii
j
d
a
Page 8A-7.1
90-8M0168224 68391
Color Diagrams
150 FourStroke Oil Flow Diagram
a- Camshaft
b- Ball stud adjusters
c- Cylinder head
d- Connecting rods
e- Cylinder block
f- Crankshaft
g- Balance shaft chain tensioner
h- Balance shaft assembly
i- Oil pump
j- Oil pressure relief valve
k- Oil pickup tube
l- Adapter plate
m- Oil sump
n- Oil filter
o- Camshaft chain tensioner

Color Diagrams
Notes:

150/150 SeaPro/150 Pro XS FourStroke
150/150 SeaPro/
150 Pro XS
S ERV IC E M A NUA L
FourStroke
S ERVI CE
MANUAL
1B905505 and Above

Serial Numbers
AUGUST 2020
90-8M0168224
www.mercurymarine.com.au www.mercurymarine.com www.brunswick-marine.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
© Mercury Marine. All rights reserved. 90-8M0168224 AUGUST 2020 S er i a l N u m b er s 1 B 9 0 5 5 0 5 a n d A b o v e

Printed in U.S.A.

150/150 Seapro/ 150 Pro Xs Fourstroke: Service Manual

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150/150 Seapro/ 150 Pro Xs Fourstroke: Service Manual

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Copyright:

Available Formats

150/150 SeaPro/150 Pro XS FourStroke

1B905505 and Above

© Mercury Marine. All rights reserved. 90-8M0168224 AUGUST 2020 S er i a l N u m b er s 1 B 9 0 5 5 0 5 a n d A b o v e

Additional alerts provide information that requires special attention:

IMPORTANT: Indicates information essential to the successful completion of the task.

Page i © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

Cleanliness and Care of Product

Copyright and Trademark Information

90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page ii

Page iii © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page 1A-1

Page 1A-2 © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

Charging and Starting Specifications

90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page 1A-3

Fuel System Specifications

Page 1A-4 © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

Cylinder Block/Crankcase Specifications

90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page 1A-5

Cylinder Head Specifications

Page 1A-6 © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

Lubrication System Specifications

Power Trim Specifications

Right‑Hand Gear Housing Specifications

90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page 1A-7

Left‑Hand Gear Housing Specifications, S/N 2B172248 and Below

Left‑Hand Gear Housing Specifications, S/N 2B172249 and Above

Gear Housing Specifications (Pro XS 4.8 in.)

Gearcase Lubricant Capacity

Page 1A-8 © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page 1B-1

Lubricant, Sealant, Adhesives

81 Anti-Seize Compound Spark plug threads 92-898101389

Page 1B-2 © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

Tube Ref No. Description Where Used Part No.

Selecting Replacement Parts For Your Outboard

EPA Emissions Regulations

Emission Certification Label

90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page 1B-3

Inspection and Maintenance Schedule

Description Nm lb‑in. lb‑ft

After Each Use

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

Page 1B-4 © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

Before Periods of Storage

Maintenance Schedule Decal 150

150 EFI FourStroke

90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page 1B-5

150 FourStroke SeaPro

Icon Definition Icon Definition

Page 1B-6 © 2020 Mercury Marine 90-8M0168224 eng AUGUST 2020

Icon Definition Icon Definition

Engine oil and filter Gearcase lubricant

Spark plugs Thermostat

Low‑pressure fuel filter Anodes

Water pump impeller

Flushing the Cooling System

Top Cowl Removal and Installation

90-8M0168224 eng AUGUST 2020 © 2020 Mercury Marine Page 1B-7

Cleaning Care for Top and Bottom Cowls

Cleaning and Waxing Procedure