151463852-200-through-to-275hp-verado

Page iii

Service Manual Outline1 - Important Information

A - Master SpecificationsB - MaintenanceC - General InformationD - Outboard Motor Installation

2 - ElectricalA - IgnitionB - Charging and Starting SystemC - Timing, Synchronizing and AdjustingD - Digital Throttle and Shift

3 - Fuel SystemA - Fuel System OperationB - Troubleshooting and DiagnosticsC - Service ProceduresD - Emissions

4 - PowerheadA - Cylinder Block/CrankcaseB - Cylinder HeadC - Lubrication

5 - Mid-SectionA - Pedestal/Mount Cradle and Driveshaft HousingB - Adapter PlateC - Power Trim

6 - Lower UnitA - Right Hand RotationB - Left Hand Rotation

7 - AttachmentsA - Attachments

8 - Power SteeringA - Power Steering

9 - Colored Wire DiagramsA - Colored Wire Diagrams

Important Information 1Electrical 2Fuel System 3Powerhead 4Mid-Section 5Lower Unit 6Attachments 7Power Steering 8Colored Wire Diagrams 9

Page i

Notice to Users of This ManualThroughout this publication, Dangers, Warnings and Cautions (accompanied by theInternational HAZARD Symbol ! ) are used to alert the mechanic to special instructionsconcerning a particular service or operation that may be hazardous if performed incorrectlyor carelessly. OBSERVE THEM CAREFULLY!These safety alerts alone cannot eliminate the hazards that they signal. Strict complianceto these special instructions when performing the service, plus common sense operation,are major accident prevention measures.

! DANGERDANGER - indicates an imminently hazardous situation that, if not avoided, will result indeath or serious injury.

! WARNINGWARNING - indicates a potentially hazardous situation that, if not avoided, could resultin death or serious injury.

! CAUTIONCAUTION - indicates a potentially hazardous situation that, if not avoided, may result inminor or moderate injury or property damage. It may also be used to alert against unsafepractices.

This service manual has been written and published by the Service Department of MercuryMarine to aid our dealers mechanics and company service personnel when servicing theproducts described herein. We reserve the right to make changes to this manual withoutprior notification. 2004, Mercury MarineMercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, MercuryPrecision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo,Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort,M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registeredtrademarks of Brunswick Corporation. Mercury Product Protection logo is a registeredservice mark of Brunswick Corporation.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 serviceprocedures of Mercury Marine Power Products, including the use of mechanics commonhand tools and the special Mercury Marine or recommended tools from other suppliers.We could not possibly know of and advise the marine trade of all conceivable proceduresand of the possible hazards and/or results of each method. Therefore, anyone who usesa service procedure and/or tool, which is not recommended by the manufacturer, first mustcompletely satisfy himself that neither his nor the products safety will be endangered.All information, illustrations and specifications contained in this manual are based on thelatest product information available at the time of publication. As required, revisions to thismanual will be sent to all dealers contracted by us to sell and/or service these products.Refer to dealer service bulletins, operation maintenance and warranty manuals andinstallation manuals for other pertinent information concerning the products described inthis manual.

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PrecautionsIt should be kept in mind, while working on the product, that the electrical and ignitionsystems are capable of violent and damaging short circuits or severe electrical shocks.When performing any work where electrical terminals could possibly be grounded ortouched 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 becovered to protect against accidental entrance of foreign material which could enter thecylinders and cause extensive internal damage when the engine is started.It is important to note, during any maintenance procedure replacement fasteners must havethe same measurements and strength as those removed. Numbers on the heads of themetric bolts and on the surfaces of metric nuts indicate their strength. American bolts useradial lines for this purpose, while most American nuts do not have strength markings.Mismatched or incorrect fasteners can result in damage or malfunction, or possiblypersonal injury. Therefore, fasteners removed should be saved for reuse in the samelocations whenever possible. Where the fasteners are not satisfactory for reuse, careshould be taken to select a replacement that matches the original.

Replacement PartsUse of parts other than the recommended service replacement parts, will void the warrantyon those parts that are damaged as a result.

! WARNINGElectrical, ignition and fuel system components on Mercury Marine Power Products aredesigned and manufactured to comply with U.S. Coast Guard Rules and Regulations tominimize risks of fire or explosion.Use of replacement electrical, ignition or fuel system components, which do not complyto these rules and regulations, could result in a fire or explosion hazard and should beavoided.When servicing the electrical, ignition and fuel systems, it is extremely important that allcomponents are properly installed and tightened. If not, any electrical or ignitioncomponent opening would permit sparks to ignite fuel vapors from fuel system leaks, ifthey existed.

Cleanliness and Care of ProductA Mercury Marine Power Product is a combination of many machined, honed, polished andlapped surfaces with tolerances that are measured in the ten thousands of an inch/mm.When any product component is serviced, care and cleanliness are important. Throughoutthis manual, it should be understood that proper cleaning and protection of machinedsurfaces and friction areas is a part of the repair procedure. This is considered standardshop practice even if not specifically stated.Whenever components are removed for service, they should be retained in order. At thetime of installation, they should be installed in the same locations and with the same matingsurfaces as when removed.Personnel should not work on or under an engine that is suspended. Engines should beattached to work stands, or lowered to ground as soon as possible.

Master Specifications

90-896580100 JULY 2004 Page 1A-1

1AImportant Information

Section 1A - Master SpecificationsTable of Contents200/225/250/275 Verado Master Specifications.........................................................................1A-2

General Specifications..............................1A-2Fuel System Specifications.......................1A-2Ignition Specifications...............................1A-3Charging and Starting Specifications........1A-3Cylinder Head Specifications....................1A-4Cylinder Block/Crankcase Specifications..................................................................1A-5Power Trim Specifications........................1A-5

Oil System Specifications.........................1A-6Gear Housing Specifications (StandardRotation)...................................................1A-6Gear Housing Specifications (CounterRotation)...................................................1A-6Power Steering Specifications..................1A-6

Propeller Chart.................................................1A-7Mercury/Mariner 200 (6 Cyl., 4 Stroke).....1A-7Mercury/Mariner 225 (6 Cyl., 4 Stroke).....1A-8Mercury/Mariner 250 (6 Cyl., 4 Stroke)...1A-10Mercury/Mariner 275 (6 Cyl., 4 Stroke)...1A-12


Page 1A-2 90-896580100 JULY 2004

200/225/250/275 Verado Master SpecificationsGeneral Specifications

Model Specifications

Kilowatts (Horsepower)149 kw (200 HP)168 kw (225 HP)186 kw (250 HP)205 kw (275 HP)

Weight 50.8 cm (20 in.) 293 kg (645 lbs.) 63.5 cm (25 in.) 299 kg (659 lbs.) 76.2 cm (30 in.) 307 kg (677 lbs.)Displacement (All Hp) 2.6L (158.5 cu. in.)RPM Idle 550 50 RPM WOT 5800 - 6400 RPMInduction System SmartCraft DTS electronic throttle, intercooled supercharged aspiration withelectronic boost pressure controlFuel System Computer controlled sequential multi-port Electronic Fuel InjectionIgnition System SmartCraft Propulsion Control Module (PCM) 03 digital inductiveCharging System Regulated belt driven 70 amp alternatorExhaust System Through propCooling System Water cooled - thermostat with pressure controlLubrication System Integrated dry sump 7 Liters (7.4 qts.)Engine Control System SmartCraft PCM 03 Digital Throttle and Shift (DTS)Trim System SmartCraft programmable Maximum Tilt Range 73 (-6 to 67) Maximum Trim Range 20 (-6 to 14)Steering System Electric - Hydraulic Power Steering with integral hydraulic cylinder

Fuel System SpecificationsFuel System Specifications

Type of fuel 149 kw (200 hp), 168 kw (225 hp), 186 kw (250 hp) Automotive unleaded with a minimum pump postedoctane rating of 87 (90 RON) 205 kw (275 hp) Automotive unleaded with a minimum pump postedoctane rating of 91 (96 RON)Approximate fuel pressure @ idle 279 - 289 kPa (40 - 42 psi)Fuel filtration Fuel inlet water separator 2 Microns High pressure 20 Microns


90-896580100 JULY 2004 Page 1A-3

Ignition SpecificationsIgnition Specifications

Full Throttle RPM (All Models) 5800 - 6400Idle RPM (All Models) 550Ignition Type Digital InductiveSpark Plug Type NGK ILFR6GSpark Plug Gap 0.8 mm (0.031 in.)Spark Plug Hex Size 16 mmSpark Plug Torque 27.5 Nm (19 lb. ft.)Spark Plug Hole Size 14 mmFiring Order 1-3-5-6-4-2Ignition Timing @ Idle Not Adjustable; Controlled by PCMIgnition Timing @ WOT Not Adjustable; Controlled by PCMPCM Over Speed Limiter Activates @ 6500 RPM

Charging and Starting SpecificationsCharging and Starting Specifications

Alternator Output (Regulated) Output @ Battery (@ 1000 RPM) 37 - 44 Amperes Output @ Battery (@ 3000 RPM) 53 - 69 Amperes Output @ Alternator (@ 1000 RPM) 48 - 54 Amperes Output @ Alternator (@ 3000 RPM) 65 - 72 AmperesVoltage Set Point 14.5 +/- 0.25 VoltsRegulator Current Draw1. Ignition Switch "OFF" (maximum) 1.0 mA Ignition Switch "ON" 350 mAStarter Draw (Under Load) 160 AmperesStarter Draw (No Load) 60 AmperesMinimum Brush Length 65.4 mm (0.25 in.)Battery Rating Marine Cranking Amperes (minimum) 1000 Cold Cranking Amperes (minimum) 800 Ampere Hour (Ah) (minimum) 180

1. All model alternator specifications require an amperage draw of less than 1.0 mA with the ignition key in the "OFF" position and anamperage draw of not more than 350.0 mA with key in the "ON" position.


Page 1A-4 90-896580100 JULY 2004

Cylinder Head SpecificationsCylinder Head Specifications

Maximum deck warp 0.075 mm (0.003)Number of valves 24Number of valves per cylinder 4Number of cams 2Cam bearing journal (intake and exhaust) 28.95 mm (1.1398 in.)Camshaft bearing cap ID 29.000 - 29.021 mm (1.1417 - 1.1425 in. )Cam lobe Intake 42.50 mm (1.6732 in.) Exhaust 43.55 mm 1.7145 in.)Valve lash Intake 0.150 - 0.230 mm (0.0059 - 0.009) Exhaust 0.350 - 0.430 mm (0.0137 - 0.0169 in.)Valve seat angles 30, 45, 60Valve spring free length 48.77 mm (1.920 in.)Valve outside diameter Intake 32.0 0.15 mm (1.259 0.0059 in.) Exhaust 27.2 mm 0.190 (1.0708 0.0059 in.)Valve face width (intake and exhaust) 2.25 mm (0.0886 in.)Valve margin Intake 0.75 mm (0.0295 in.) Exhaust 0.65 mm (0.0256 in.)Valve guide bore ID (intake and exhaust) 6.00 - 6.016mm (0.2362 - 0.2368 in.)Valve stem diameter Intake 5.97 mm (0.235 in.) Exhaust 5.96 mm (0.2346 in.)Valve stem run-out (maximum) 0.038 mm (0.0015 in.)Valve stem to valve guide clearance Intake 0.03 - 0.046 mm (0.0011 - 0.0018 in.) Exhaust 0.04 - 0.056 mm (0.0015 - 0.0022 in.)Valve seat contact width (intake and exhaust) 2.25 mm (0.0886 in.)


90-896580100 JULY 2004 Page 1A-5

Cylinder Block/Crankcase SpecificationsCylinder Block/Crankcase Specifications

Number of cylinders 6Displacement 2.6 Liters (158.6 CID)Compression ratio 8.25:1Standard bore 82.00 mm (3.228 in.)Stroke 82.0 mm (3.228 in.)Cylinder bore maximum taper (service) 0.0762 mm (0.003 in.)Cylinder bore maximum out of round (service) 0.0762 mm (0.003 in.)Cylinder block main bearing 65.997 - 66.013 mm (2.5982 - 2.5989 in.)Crankshaft main bearing journal 59.985 - 60.001 mm (2.3616 - 2.3622 in.)Crankshaft pin journal 49.982 - 50.0 mm (1.9678 - 1.968 in.)Crankshaft end play 0.08 - 0.19 mm mm (0.003 - 0.007 in.)Crankshaft run out 0.05 mm (0.002 in.)Crankshaft main bearing oil clearance (without expansion) 0.014 - 0.042 mm (0.0005 - 0.0016 in.)Crankshaft pin bearing oil clearance (without expansion) 0.020 - 0.050 mm (0.0008 - 0.0019 in.)Connecting rod wrist pin bore diameter 22.005 - 22.014 mm (0.8663 - 0.8666 in.)Connecting rod crankshaft pin diameter 53.000 - 53.018 mm (2.0866 - 2.0873 in.)Piston skirt standard diameter 81.975 mm (3.2273 in.)Piston wrist pin bore diameter 22.004 - 22.011 mm (0.8662 - 0.8665 in.)Wrist pin diameter 21.997 - 22.000 mm (0.8660 - 0.8661 in.)Top ring grove width 1.25 mm (0.049 in.)Second ring grove width 1.25 mm (0.049 in.)Third ring grove width 2.05 mm (0.081 in.)Top ring thickness 1.19 mm (0.047 in.)Second ring thickness 1.19 mm (0.047 in.)Third ring thickness 1.98 mm (0.078 in.)Top ring side clearance 0.04 - 0.08 mm (0.001 - 0.003 in.)Second ring side clearance 0.04 - 0.08 mm (0.001 - 0.003 in.)Third ring side clearance 0.05 - 0.17 mm (0.002 - 0.006Top ring end gap 0.27 - 0.42 mm (0.010 - 0.016 in.)Second ring end gap 0.42 - 0.62 mm (0.016 - 0.024 in.)Oil ring end gap 0.2 - 0.7 mm (0.007 - 0.027 in.)

Power Trim SpecificationsPower Trim Specifications

Trim up circuit pressure, maximum 18,270 - 28,960 kPa (2650 - 4200 psi)Trim down circuit pressure 1255 - 2765 kPa (182 - 401 psi)System fluid Power Trim and Steering Fluid or Automatic Transmission Fluid (ATF)(Type Dexron III)


Page 1A-6 90-896580100 JULY 2004

Oil System SpecificationsOil System Specifications

Engine Capacity Wet 7 liters (7.4 qts.)Engine Capacity Dry 8 liters (8.4 qts.)Oil Filter Part Number 35-883701K01Oil Pressure (Minimum) @ 550 RPM 70 kPa (10 psi)Oil Pressure (Minimum) @ 6000 RPM 220 kPa (32 psi)IOM thermostat opening temperature 105 C (221 F)

Gear Housing Specifications (Standard Rotation)Gear Housing Specifications (Standard Rotation)

Gear Ratio 1.85:1 (13/24 Teeth)Gearcase Capacity 970 ml (32.8 fl.oz.)Gear Lubricant Type Premium Gear LubricantPinion Height 0.635 mm (0.025 in.)Forward Gear Backlash 0.482 - 0.660 mm (0.019 - 0.026 in.)Reverse Gear Backlash 1.27 - 1.47 mm (0.050 - 0.058 in.)Water Pressure @ RPM 55 - 68.9 kPa (8 - 10 psi)Gear Housing Pressure (without gear lubricant, 5 minutes withoutleakage) 103.4 kPa (15 psi)

Gear Housing Specifications (Counter Rotation)Gear Housing Specifications (Counter Rotation)

Gear Ratio 1.85:1 (13/24 Teeth)Gearcase Capacity 970 ml (32.8 fl.oz.)Gear Lubricant Type Premium Gear LubricantPinion Height 0.635 mm (0.025 in.)Forward Gear Backlash 0.482 - 0.660 mm (0.019 - 0.026 in.)Reverse Gear Backlash 1.27 - 1.47 mm (0.050 - 0.058 in.)Water Pressure @ RPM 55 - 68.9 kPa (8 - 10 psi)Gear Housing Pressure (without gear lubricant, 5 minutes withoutleakage) 103.4 kPa (15 psi)

Power Steering SpecificationsPower Steering Specifications

Fluid Type SAE 0W-30 synthetic power steering fluidCapacity Typical 1 - 2 liters (1 - 2 quarts)Current Draw Shall not exceed 75 AmpsSteering Ratio (40 cc helm and single steering cylinder, lock tolock) 4.1 turnsSteering Ratio (50 cc helm with dual steering cylinders, lock tolock) 6.5 turns


90-896580100 JULY 2004 Page 1A-7

Propeller ChartMercury/Mariner 200 (6 Cyl., 4 Stroke)

Wide Open Throttle RPM: 5800 - 6400 Recommended Transom Height: 50.8 cm (20 in.), 63.5 cm (25 in.), 76.2 cm (30 in.) Gear Reduction: 1.85:1 Right Hand Rotation (RH), Left Hand Rotation (LH)

Diameter Pitch No. ofBlades Model Approx. Gross Boat Wgt.Approx. Boat

Length Speed RangePropeller Part

Number13.75 27 4 Trophy Plus Up to952.54 Kg(2100 lbs.)

Up to 6.4 m(21 ft.)

120.70 - 136.8 km(75 - 85 MPH) 48-825946A47

14.62 27 3 Tempest Plus Up to952.54 Kg(2100 lbs.)Up to 6.4 m

(21 ft.)120.70 - 136.8 km

(75 - 85 MPH) 48-825868A47

15.25 26 4 Bravo 1 861.83 - 997.7 Kg(1900-2200 lbs.)6.4 - 7.0 m(21 - 23 ft.)

115.87 - 130.4 km(72 - 81 MPH)

48-831914A45(RH)

48-831913A45(LH)

13.75 26 4 Trophy Plus 861.83 - 997.7 Kg(1900-2200 lbs.)6.4 - 7.0 m(21 - 23 ft.)

115.87 - 130.4 km(72 - 81 MPH) 48-825944A47

14.62 26 3 Tempest Plus 861.83 - 997.7 Kg(1900-2200 lbs.)6.4 - 7.0 m(21 - 23 ft.)

115.87 - 130.4 km(72 - 81 MPH) 48-825874A47

14.50 25 3 Mirage Plus 907.18 - 1043.26 Kg(2000-2300 lbs.)6.4 - 7.0 m(21 - 23 ft.)

111.04 - 125.53 km(69 - 78 MPH)

48-13706A46(RH)

48-13707A46 (LH)13.75 25 4 Trophy Plus 907.18 - 1043.26 Kg(2000-2300 lbs.)

6.4 - 7.0 m(21 - 23 ft.)

111.04 - 125.53 km(69 - 78 MPH) 48-825942A47


111.04 - 125.53 km(69 - 78 MPH) 48-825866A47

15.25 24 4 Bravo I 952.54 - 1088.62 Kg(2100-2400 lbs.)6.7 - 7.3 m(22 - 24 ft.)

106.22 - 119.09 km(66 - 74 MPH)

48-831912A45(RH)

48-831911A45(LH)


106.22 - 119.09 km(66 - 74 MPH) 48-825940A47


106.22 - 119.09 km(66 - 74 MPH) 48-825872A47

14.62 23 4 Revolution 4 997.90 - 1133.98 Kg(2200-2500 lbs.)6.7 - 7.3 m(22 - 24 ft.)

101.39 - 114.26 km(63 - 71 MPH)

48-857030A46(RH)

48-857031A46(LH)


101.39 - 114.26 km(63 - 71 MPH) 48-825938A47


101.39 - 114.26 km(63 - 71 MPH) 48-825864A47


101.39 - 114.26 km(63 - 71 MPH)

48-13704A46(RH)

48-13705A46 (LH)13.25 23 5 High Five 997.90 - 1133.98 Kg(2200-2500 lbs.)

6.7 - 7.3 m(22 - 24 ft.)

101.39 - 114.26 km(63 - 71 MPH) 48-815762A46


Page 1A-8 90-896580100 JULY 2004



Number

14.00 23 4 VenSura 997.90 - 1133.98 Kg(2200-2500 lbs.)6.7 - 7.3 m(22 - 24 ft.)

101.39 - 114.26 km(63 - 71 MPH)

48-825906A48(RH)

48-825907A48(LH)


91.73 - 103.0 km(57 - 64 MPH) 48-825934A47


91.73 - 103.0 km(57 - 64 MPH) 48-825862A47


91.73 - 103.0 km(57 - 64 MPH)

48-13702A46(RH)


6.7 - 7.3 m(22 - 24 ft.)

91.73 - 103.0 km(57 - 64 MPH) 48-815760A46


91.73 - 103.0 km(57 - 64 MPH)

48-825902A48(RH)

48-825903A48(LH)


82.08 - 93.34 km(51 - 58 MPH) 48-825860A47


82.08 - 93.34 km(51 - 58 MPH)

48-13700A46(RH)


6.7 - 7.6 m(22 - 25 ft.)

82.08 - 93.34 km(51 - 58 MPH) 48-815758A46


82.08 - 93.34 km(51 - 58 MPH)

48-825900A48(RH)

48-825901A48(LH)


72.42 - 83.69 km(45 - 52 MPH)

48-18278A46(RH)


6.7 - 7.9 m(22 - 26 ft.)

72.42 - 83.69 km(45 - 52 MPH) 48-821154A46


72.42 - 83.69 km(45 - 52 MPH)

48-825898A48(RH)

48-825899A48(LH)

15.75 15 3 Mirage Plus 1632.93- 1995.81 Kg(3600-4400 lbs.)6.7 - 7.9 m(22 - 26 ft.)

61.16 - 75.64 km(38 - 47 MPH)

48-19838A46(RH)

48-19841A46 (LH)16 13 3 Mirage Plus 1859.73- 2630.84 Kg(4100-5800 lbs.)

6.7 - 7.9 m(22 - 26 ft.)

49.89 - 64.37 km(31 - 40 MPH) 48-826072A46

16 12 3 Aluminum 2222.60- 3084.43 Kg(4900-6800 lbs.)7.0 - 8.2 m(23 - 27 ft.)

41.84 - 56.33 km(26 - 35 MPH) 48-16436A45

16 11 3 Aluminum 2721.55+ Kg (6000+ lbs.) Workboat 1.61 - 46.67 km(1 - 29 MPH)48-78112A45

(RH)48-78117A40 (LH)

Mercury/Mariner 225 (6 Cyl., 4 Stroke) Wide Open Throttle RPM: 5800 - 6400 Recommended Transom Height: 50.8 cm (20 in.), 63.5 cm (25 in.), 76.2 cm (30 in.) Gear Reduction: 1.85:1


90-896580100 JULY 2004 Page 1A-9

Right Hand Rotation (RH), Left Hand Rotation (LH)Diameter Pitch No. ofBlades Model Approx. Gross Boat Wgt.

Approx. BoatLength Speed Range

Propeller PartNumber

15.25 28 4 Bravo I Up to 997.90 Kg(2200 lbs.)Up to 6.7 m

(22 ft.)125.53-141.62 km

(78-88 MPH)48-831916A55

(RH)48-831915A55

(LH)13.75 28 4 Trophy Plus Up to 997.90 Kg(2200 lbs.)

Up to 6.7 m(22 ft.)

125.53-141.62 km(78-88 MPH) 48-825948A47

13.75 27 4 Trophy Plus 907.18-1043.26 Kg(2000-2300 lbs.)Up to 6.7 m

(22 ft.)120.70-136.8 km

(75-85 MPH) 48-825946A47

14.62 27 3 Tempest Plus 907.18-1043.26 Kg(2000-2300 lbs.)Up to 6.7 m

(22 ft.)120.70-136.8 km

(75-85 MPH) 48-825868A47

15.25 26 4 Bravo I 952.54-1088.62 Kg(2100-2400 lbs.)6.4-7.0 m(21-23 ft.)

115.87-130.4 km(72-81 MPH)

48-831914A45(RH)

48-831913A45(LH)

13.75 26 4 Trophy Plus 952.54-1088.62 Kg(2100-2400 lbs.)6.4-7.0 m(21-23 ft.)

115.87-130.4 km(72-81 MPH) 48-825944A47

14.62 26 3 Tempest Plus 952.54-1088.62 Kg(2100-2400 lbs.)6.4-7.0 m(21-23 ft.)

115.87-130.4 km(72-81 MPH) 48-825874A47

14.50 25 3 Mirage Plus 997.90-1133.98 Kg(2200-2500 lbs.)6.4-7.0 m(21-23 ft.)

111.04-125.53 km(69-78 MPH)

48-13706A46 (RH)48-13707A46 (LH)


111.04-125.53 km(69-78 MPH) 48-825942A47


111.04-125.53 km(69-78 MPH) 48-825866A47

15.25 24 4 Bravo I 1088.62-1224.70 Kg(2400-2700 lbs.)6.7-7.3 m(22-24 ft.)

106.22-119.09 km(66-74 MPH)

48-831912A45(RH)

48-831911A45(LH)


106.22-119.09 km(66-74 MPH) 48-825940A47


106.22-119.09 km(66-74 MPH) 48-825872A47

14.62 23 4 Revolution 4 1133.98-1270.06 Kg(2500-2800 lbs.)6.7-7.3 m(22-24 ft.)

101.39-114.26 km(63-71 MPH)

48-857030A46(RH)

48-857031A46(LH)


101.39-114.26 km(63-71 MPH) 48-825938A47


101.39-114.26 km(63-71 MPH) 48-825864A47


101.39-114.26 km(63-71 MPH)

48-13704A46 (RH)48-13705A46 (LH)

13.25 23 5 HighFive 1133.98-1270.06 Kg(2500-2800 lbs.)6.7-7.3 m(22-24 ft.)

101.39-114.26 km(63-71 MPH) 48-815762A46

14.00 23 4 VenSura 1133.98-1270.06 Kg(2500-2800 lbs.)6.7-7.3 m(22-24 ft.)

101.39-114.26 km(63-71 MPH)

48-825906A48(RH)

48-825907A48(LH)


91.73-103.0 km(57-64 MPH) 48-825934A47


Page 1A-10 90-896580100 JULY 2004



Number14.62 21 3 Tempest Plus 1270.06-1451.50 Kg(2800-3200 lbs.)

6.7-7.3 m(22-24 ft.)

91.73-103.0 km(57-64 MPH) 48-825862A47


91.73-103.0 km(57-64 MPH)

48-13702A46 (RH)48-13703A46 (LH)


91.73-103.0 km(57-64 MPH) 48-815760A46


91.73-103.0 km(57-64 MPH)

48-825902A48(RH)

48-825903A48(LH)


82.08-93.34 km(51-58 MPH) 48-825860A47


82.08-93.34 km(51-58 MPH)

48-13700A46 (RH)48-13701A46 (LH)


82.08-93.34 km(51-58 MPH) 48-815758A46


82.08-93.34 km(51-58 MPH)

48-825900A48(RH)

48-825901A48(LH)


72.42-83.69 km(45-52 MPH)

48-18278A46 (RH)48-90159A46 (LH)


72.42-83.69 km(45-52 MPH) 48-821154A46


72.42-83.69 km(45-52 MPH)

48-825898A48(RH)

48-825899A48(LH)


56.33-72.42 km(35-45 MPH)

48-19838A46 (RH)48-19841A46 (LH)

16 13 3 Mirage Plus 2267.96 + Kg(5000 + lbs.)7.6-9.1 m(25-30 ft.)

40.23-61.16 km(25-38 MPH) 48-825072A46

Mercury/Mariner 250 (6 Cyl., 4 Stroke) Wide Open Throttle RPM: 5800 - 6400 Recommended Transom Height: 50.8 cm (20 in.), 63.5 cm (25 in.), 76.2 cm (30 in.) Gear Reduction: 1.85:1 Right Hand Rotation (RH), Left Hand Rotation (LH)



Number


(22 ft.)125.53-141.62 km

(78-88 MPH)48-831916A55

(RH)48-831915A55


Up to 6.7 m(22 ft.)

125.53-141.62 km(78-88 MPH) 48-825948A47


(22 ft.)120.70-136.8 km

(75-85 MPH) 48-825946A47

14.62 27 3 Tempest Plus 997.90-1179.34(2200-2600 lbs.)Up to 6.7 m

(22 ft.)120.70-136.8 km

(75-85 MPH) 48-825868A47


90-896580100 JULY 2004 Page 1A-11



Number

15.25 26 4 Bravo I 1088.62-1224.70 Kg(2400-2700 lbs.)6.4-7.0 m(21-23 ft.)

115.87-130.4 km(72-81 MPH)

48-831914A45(RH)

48-831913A45(LH)


115.87-130.4 km(72-81 MPH) 48-825944A47


115.87-130.4 km(72-81 MPH) 48-825874A47


111.04-125.53 km(69-78 MPH)

48-13706A46 (RH)48-13707A46 (LH)


111.04-125.53 km(69-78 MPH) 48-825942A47


111.04-125.53 km(69-78 MPH) 48-825866A47

15.25 24 4 Bravo I 1179.34-1360.78 Kg(2600-3000 lbs.)6.7-7.3 m(22-24 ft.)

106.22-119.09 km(66-74 MPH)

48-831912A45(RH)

48-831911A45(LH)


106.22-119.09 km(66-74 MPH) 48-825940A47


106.22-119.09 km(66-74 MPH) 48-825872A47


101.39-114.26 km(63-71 MPH)

48-857030A46(RH)

48-857031A46(LH)


101.39-114.26 km(63-71 MPH) 48-825938A47


101.39-114.26 km(63-71 MPH) 48-825864A47


101.39-114.26 km(63-71 MPH)

48-13704A46 (RH)48-13705A46 (LH)


101.39-114.26 km(63-71 MPH) 48-815762A46


101.39-114.26 km(63-71 MPH)

48-825906A48(RH)

48-825907A48(LH)


91.73-103.0 km(57-64 MPH) 48-825934A47


91.73-103.0 km(57-64 MPH) 48-825862A47


91.73-103.0 km(57-64 MPH)

48-13702A46 (RH)48-13703A46 (LH)


91.73-103.0 km(57-64 MPH) 48-815760A46


91.73-103.0 km(57-64 MPH)

48-825902A48(RH)

48-825903A48(LH)


82.08-93.34 km(51-58 MPH) 48-825860A47


Page 1A-12 90-896580100 JULY 2004



Number15.25 19 3 Mirage Plus 1542.21-1814.37 Kg(3400-4000 lbs.)

6.7-7.6 m(22-25 ft.)

82.08-93.34 km(51-58 MPH)

48-13700A46 (RH)48-13701A46 (LH)


82.08-93.34 km(51-58 MPH) 48-815758A46


82.08-93.34 km(51-58 MPH)

48-825900A48(RH)

48-825901A48(LH)


62.76-78.86 km(39-49 MPH)

48-18278A46 (RH)48-90159A46 (LH)


62.76-78.86 km(39-49 MPH) 48-851154A46


62.76-78.86 km(39-49 MPH)

48-825898A48(RH)

48-825899A48(LH)


56.33-72.42 km(35-45 MPH)

48-19838A46 (RH)48-19841A46 (LH)


40.23-61.16 km(25-38 MPH) 48-826072A46

Mercury/Mariner 275 (6 Cyl., 4 Stroke) Wide Open Throttle RPM: 5800 - 6400 Recommended Transom Height: 50.8 cm (20 in.), 63.5 cm (25 in.), 76.2 cm (30 in.) Gear Reduction: 1.85:1 Right Hand Rotation (RH), Left Hand Rotation (LH)



Number


(22 ft.)125.53-141.62 km

(78-88 MPH)48-831916A55

(RH)48-831915A55


Up to 6.7 m(22 ft.)

125.53-141.62 km(78-88 MPH) 48-825948A47


(22 ft.)120.70-136.8 km

(75-85 MPH) 48-825946A47

14.62 27 3 Tempest Plus 1133.98-1270.06 Kg(2500-2800 lbs.)Up to 6.7 m

(22 ft.)120.70-136.8 km

(75-85 MPH) 48-825868A47

15.25 26 4 Bravo I 1179-34-1360.78 Kg(2600-3000 lbs.)6.4-7.0 m(21-23 ft.)

115.87-130.4 km(72-81 MPH)

48-831914A45(RH)

48-831913A45(LH)

13.75 26 4 Trophy Plus 1179-34-1360.78 Kg(2600-3000 lbs.)6.4-7.0 m(21-23 ft.)

115.87-130.4 km(72-81 MPH) 48-825944A47

14.62 26 3 Tempest Plus 1179-34-1360.78 Kg(2600-3000 lbs.)6.4-7.0 m(21-23 ft.)

115.87-130.4 km(72-81 MPH) 48-825874A47


111.04-125.53 km(69-78 MPH)

48-13706A46 (RH)48-13707A46 (LH)


111.04-125.53 km(69-78 MPH) 48-825942A47


90-896580100 JULY 2004 Page 1A-13



Number14.62 25 3 Tempest Plus 1224.70-1406.14 Kg(2700-3100 lbs.)

6.4-7.0 m(21-23 ft.)

111.04-125.53 km(69-78 MPH) 48-825866A47

15.25 24 4 Bravo I 1315.42-1496.86 Kg(2900-3300 lbs.)6.7-7.3 m(22-24 ft.)

106.22-119.09 km(66-74 MPH)

48-831912A45(RH)

48-831911A45(LH)


106.22-119.09 km(66-74 MPH) 48-825940A47


106.22-119.09 km(66-74 MPH) 48-825872A47


101.39-114.26 km(63-71 MPH)

48-857030A46(RH)

48-857031A46(LH)


101.39-114.26 km(63-71 MPH) 48-825938A47


101.39-114.26 km(63-71 MPH) 48-825864A47


101.39-114.26 km(63-71 MPH)

48-13704A46 (RH)48-13705A46 (LH)


101.39-114.26 km(63-71 MPH) 48-815762A46


101.39-114.26 km(63-71 MPH)

48-825906A48(RH)

48-825907A48(LH)


91.73-103.0 km(57-64 MPH) 48-825934A47


91.73-103.0 km(57-64 MPH) 48-825862A47


91.73-103.0 km(57-64 MPH)

48-13702A46 (RH)48-13703A46 (LH)


91.73-103.0 km(57-64 MPH) 48-815760A46


91.73-103.0 km(57-64 MPH)

48-825902A48(RH)

48-825903A48(LH)


82.08-93.34 km(51-58 MPH) 48-825860A47


82.08-93.34 km(51-58 MPH)

48-13700A46 (RH)48-13701A46 (LH)


82.08-93.34 km(51-58 MPH) 48-815758A46


82.08-93.34 km(51-58 MPH)

48-825900A48(RH)

48-825901A48(LH)


62.76-78.86 km(39-49 MPH)

48-18278A46 (RH)48-90159A46 (LH)


62.76-78.86 km(39-49 MPH) 48-821154A46


Page 1A-14 90-896580100 JULY 2004



Number


62.76-78.86 km(39-49 MPH)

48-825898A48(RH)

48-825899A48(LH)

15.75 15 3 Mirage Plus 2267.96-2948-35 Kg(5000-6500 lbs.)7.0-8.2 m(23-27 ft.)

56.33-72.42 km(35-45 MPH)

48-19838A46 (RH)48-19841A46 (LH)


40.23-61.16 km(25-38 MPH) 48-826072A46

Maintenance

90-896580100 JULY 2004 Page 1B-1

1BImportant InformationSection 1B - Maintenance

Table of ContentsSpecial Tools - Maintenance............................1B-2Outboard Care.................................................1B-3

Selecting Replacement Parts For YourOutboard...................................................1B-3

EPA Regulations..............................................1B-3EPA Emissions................................................1B-4

Emission Certification Label.....................1B-4Owner Responsibility................................1B-4

Inspection And Maintenance Schedule............1B-4Before Each Use.......................................1B-4After Each Use..........................................1B-4Every 100 Hours Of Use Or Once Yearly,Whichever Occurs First............................1B-4Every 300 Hours Of Use Or Three Years..................................................................1B-5Before Periods Of Storage........................1B-5

Flushing The Cooling System..........................1B-5Cowl Removal and Installation.........................1B-6

Cowl Removal...........................................1B-6Cowl Installation........................................1B-7

Exterior Care....................................................1B-7Battery Inspection ...........................................1B-7DTS Battery Specifications..............................1B-7Air Filter............................................................1B-8

Air Filter Removal and Cleaning...............1B-8Air Filter Installation..................................1B-9

Fuel System...................................................1B-10Fuel Line Inspection................................1B-10

Water Separating Fuel Filter...................1B-10Corrosion Control Anode...............................1B-12Propeller Replacement..................................1B-13Spark Plug Inspection and Replacement.......1B-14Fuses.............................................................1B-15DTS Wiring System........................................1B-16Accessory Drive Belt Inspection....................1B-17Checking Power Trim Fluid............................1B-17Checking Power Steering Fluid......................1B-18Changing Engine Oil .....................................1B-18

Engine Oil Capacity................................1B-18Pump Method.........................................1B-18Drain Method..........................................1B-18Changing Oil Filter .................................1B-19Oil Filling.................................................1B-20

Storage Preparation.......................................1B-20Fuel System............................................1B-20

Protecting External Outboard Components.. .1B-21Protecting Internal Engine Components........1B-21Gearcase.......................................................1B-21Positioning Outboard For Storage.................1B-21Battery Storage..............................................1B-21Gearcase Lubrication.....................................1B-21

Draining Gearcase..................................1B-21Gearcase Lubricant Capacity.................1B-22Gearcase Lubricant Recommendation...1B-22Checking Lubricant Level and RefillingGearcase................................................1B-22

Submerged Outboard....................................1B-22

Maintenance

Page 1B-2 90-896580100 JULY 2004

Lubricant, Sealant, AdhesivesTube Ref No. Description Where Used Part No.

94 Anti-Corrosion Grease Propeller shaft splines 92-802867A195 2-4-C Marine Lubricant with Teflon Propeller shaft splines 92-802859A1

Special Tools - MaintenanceOil Drain Funnel 91-892866A01

4993

Diverts draining engine oil from contacting the anti-splash andanti-cavitation plates.

Flushing Attachment 44357T2

5218

Attaches to gearcase water intake, to provide a fresh waterconnection when flushing the cooling system or operating theengine out of water

Crankcase Oil Pump 91-90265A5

5220

Alternate tool for draining engine oil sump.

Oil Filter Wrench 91-895277001

5221

Assists in removing oil filter.

Maintenance

90-896580100 JULY 2004 Page 1B-3

Dual Water Pick-up Flushing Seal Kit 91-881150Q1

5235

Blocks off the front water inlet holes on the dual water inletgearcase.

Outboard CareTo keep your outboard in the best operating condition, it is important that your outboardreceive the periodic inspections and maintenance listed in the Inspection and MaintenanceSchedule. We urge you to keep it maintained properly to ensure the safety of you and yourpassengers, and retain its dependability.

! WARNINGNeglected inspection and maintenance service of your outboard or attempting to performmaintenance or repair on your outboard if you are not familiar with the correct serviceand safety procedures could cause personal injury, death, or product failure.

Record maintenance performed in Maintenance Log at the back of this book. Save allmaintenance work orders and receipts.

Selecting Replacement Parts For Your OutboardWe recommend using original Mercury Precision or Quicksilver replacement parts andGenuine Lubricants.

! WARNINGUsing a replacement part that is inferior to the original part could result in personal injury,death, or product failure.

EPA RegulationsAll new outboards manufactured by Mercury Marine are certified to the United StatesEnvironmental Protection Agency, as conforming to the requirements of the regulations forthe control of air pollution from new outboard motors. This certification is contingent oncertain adjustments being set to factory standards. For this reason, the factory procedurefor servicing the product must be strictly followed and, wherever practicable, returned tothe original intent of the design. Maintenance, replacement, or repair of the emission controldevices and systems may be performed by any marine spark ignition (SI) engine repairestablishment or individual.

Maintenance

Page 1B-4 90-896580100 JULY 2004

EPA EmissionsEmission Certification Label

An emission certification label, showing emission levels and engine specifications directlyrelated to emissions, is placed on the engine at time of manufacture.

ob00366

c hde

ba f

i

g

a - Idle speedb - Engine horsepowerc - Piston displacementd - Date of manufacturee - Valve clearance (if applicable)

f - Family numberg - Maximum emission output for the

engine familyh - Timing specificationi - Recommended spark plug and gap

Owner ResponsibilityThe owner/operator is required to have routine engine maintenance performed to maintainemission levels within prescribed certification standards.The owner/operator is not to modify the engine in any manner that would alter thehorsepower or allow emissions levels to exceed their predetermined factory specifications.

Inspection And Maintenance ScheduleBefore Each Use

Check engine oil level. Check that lanyard stop switch stops the engine. Visually inspect the fuel system for deterioration or leaks. Check outboard for tightness on transom. Check steering system for binding or loose components. Visually check power steering fittings and hoses for leaks or signs of damage. Check

tie bar fasteners (multiple outboard rigs) for proper tightness. Check propeller blades for damage.

After Each Use Flush out the outboard cooling system if operating in salt or polluted water. . Wash off all salt deposits and flush out the exhaust outlet of the propeller and gearcase

with fresh water if operating in salt water.Every 100 Hours Of Use Or Once Yearly, Whichever Occurs First

Change engine oil and replace the oil filter. The oil should be changed more often whenthe engine is operated under adverse conditions such as extended trolling.

Maintenance

90-896580100 JULY 2004 Page 1B-5

Inspect thermostat visually for corrosion and broken spring. Make sure thermostatcloses completely at room temperature.

Check engine fuel filter for contaminants. Check corrosion control anodes. Check more frequently when used in salt water. Drain and replace gearcase lubricant. Check power steering fluid. Inspect battery. Saltwater usage. Remove and inspect spark plugs for corrosion and replace spark

plugs as necessary. Apply a thin coating of Anti-Seize Compound only on threads ofspark plug prior to installation.

Check wiring and connectors Check tightness of bolts, nuts, and other fasteners.

Every 300 Hours Of Use Or Three YearsIMPORTANT: Engine oil must be drained before removing gearcase to avoid oil spillage.Perform scheduled water pump replacement in combination with an engine oil change. Replace water pump impeller (more often if overheating occurs or reduced water

pressure is noted). Check power trim fluid. Replace spark plugs at first 300 hours or three years. After that, inspect spark plugs

every 300 hours or three years. Replace spark plugs as needed. Replace accessory drive belt.

Before Periods Of Storage Refer to Storage procedure.

Flushing The Cooling SystemFlush 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 theinternal 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. Disconnect the flush connector from fitting on the bottom cowl.

ob01236

Maintenance

Page 1B-6 90-896580100 JULY 2004

3. Thread a water hose into the flush fitting.

ob01237

4. Turn on the water tap (1/2 maximum) and let the water flush through the cooling systemfor about 15 minutes.

5. When flushing is complete, turn off water and disconnect the water hose.6. Reinstall the flushing connector to the fitting on the bottom cowl. Tighten the connector

securely.Cowl Removal and InstallationCowl Removal

IMPORTANT: Most maintenance points are accessible by removing the top cowl only.1. Pull up on the top cowl lock latch.

ob01324

2. Pull top cowl forward and lift off.3. Pull lower cowl release latch up.4. Remove rear cowl towards aft of outboard.

ob01257

Maintenance

90-896580100 JULY 2004 Page 1B-7

Cowl Installation1. Position lower cowl from aft side of outboard. Make sure it fits properly in the rubber

seal.2. Lock cowl in place by pulling lower cowl latch down.

ob01671

3. Place top cowl into position over engine, front first. Ensure cowl fits properly into therubber seal.

4. The top cowl will lock into place when downward pressure is applied to the back sideof cowl. Ensure cowl is securely fastened by pulling up on back of cowl.

Exterior CareThe outboard is protected with a durable baked enamel finish. Clean and wax often usingmarine cleaners and waxes. Do not wax textured areas of cowl.

Battery InspectionThe battery should be inspected at periodic intervals to ensure proper engine startingcapability.IMPORTANT: Read the safety and maintenance instructions which accompany yourbattery.1. Turn off the engine before servicing the battery.2. Add water as necessary to keep the battery full.3. Make sure the battery is secure against movement.4. Battery cable terminals should be clean, tight, and correctly installed. Positive to

positive and negative to negative.5. Make sure the battery is equipped with a nonconductive shield to prevent accidental

shorting of battery terminals.DTS Battery Specifications

IMPORTANT: Do not use deep cycle batteries for the main engine starting battery.IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and CoastGuard regulations must be adhered to when installing the battery. Ensure that battery cableinstallation meets the pull test requirements and that positive battery terminal is properlyinsulated in accordance with regulations.

Maintenance

Page 1B-8 90-896580100 JULY 2004

IMPORTANT: It is recommended (required in some states) that the battery be installed inan enclosed case. Refer to regulations for your area.Minimum SAE Starting Battery Requirements - BCI GRP 24 MCA 1000 CCA 800 Ah 180 (International Rating)NOTE: Due to the wide variety of battery manufactures throughout the world, ratings andphysical battery sizes will vary. Check with the manufacturer for a starting battery with aMCA, CCA, or Ah specification that will be equal to or greater than the SAE Standard J537specified above.IMPORTANT: For DTS products, each engine must be equipped with its own startingbattery. If your boat application requires additional battery loads for boat accessories ormarine electronics, it is recommended that an auxiliary battery or batteries be installed.

! CAUTIONHex nuts must be used to secure battery leads to battery posts to avoid loss of electricalpower.

When connecting engine battery, hex nuts must be used to secure battery leads to batteryposts. Torque nuts to specifications.Description Nm lb. in. lb. ft.Hex nuts 13.5 120IMPORTANT: Battery cable size and length is critical. Refer to Battery Cable Size tablesor engine installation manual for size requirements.Decal needs to be placed on or near battery box for future service reference. One5/16 in. and one 3/8 in. hex nut are supplied per battery for wing nut replacement. Metrichex nuts are not supplied.

Place decal on or near battery box for future service reference. 5/16" and 3/8" hex nuts supplied for wing nut replacement. Metric hex nuts not supplied.

NOTICE - DTS & Optimax Engines

37-895387

IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.

DO NOT USE WING NUTS.

DO NOT USE DEEP CYCLE BATTERIES!

13.5Nm (120 lbs. in.)

DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah.rating.

3486

Air FilterThe air filter assembly is a serviceable item and can be cleaned with warm soap water ifrequired.

Air Filter Removal and Cleaning1. Loosen air filter clamp screw.

Maintenance

90-896580100 JULY 2004 Page 1B-9

2. Remove crankcase ventilation hose.

3664

a

b

c

da - Crankcase ventilation hoseb - Fuel System Module (FSM) purge

valve hosec - Filter assemblyd - Clamp screw

3. Remove air filter assembly and disconnect Fuel System Module (FSM) purge valvehose by rotating the air filter assembly and pulling on hose.

3665

4. Wash air filter assembly in warm soap water.5. Dry filter assembly with compressed air.6. Apply 4-Cycle Outboard Oil on rag or towel and lightly pad air filter element. Wipe off

excess oil. Air filter element should be moist to the touch.Air Filter Installation

1. Install Fuel System Module (FSM) purge valve hose to air filter assembly.

3665

2. Install crancase ventilation hose.

Maintenance

Page 1B-10 90-896580100 JULY 2004

3. Install air filter assembly and tighten clamp screw securely.

3664

a

b

c

da - Crankcase ventilation hoseb - Fuel System Module (FSM) purge

valve hosec - Filter assemblyd - Clamp screw

Fuel System! WARNING

Avoid serious injury or death from gasoline fire or explosion. Carefully follow all fuelsystem service instructions. Always stop the engine and do not smoke or allow openflames or sparks in the area while servicing any part of the fuel system.

IMPORTANT: Use an approved container to collect and store fuel. Wipe up spilled fuelimmediately. Material used to contain spilled fuel must be disposed of in an approvedreceptacle.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 InspectionVisually inspect the fuel line for cracks, swelling, leaks, hardness, or other signs ofdeterioration or damage. If any of these conditions are found, the fuel line must be replaced.

Water Separating Fuel FilterNOTE: The warning system will turn on when water in the fuel filter reaches the full level.This filter removes moisture and debris from the fuel. If the filter holder becomes filled withwater, the water can be removed. If the filter becomes plugged with debris, replace the filter.Refer to the Inspection and Maintenance Schedule for the proper maintenance interval.

FILTER REMOVAL1. Turn ignition key switch to "OFF" position.

Maintenance

90-896580100 JULY 2004 Page 1B-11

2. Remove fuel vapor purge relief valve cap (green cap located aft of starter motor).

3470

! CAUTIONFuel vapor vent system is under pressure. Cover valve assembly with a rag or towel toprevent fuel or fuel vapor spray. Relieve pressure slowly.

3. Place rag or towel around valve, release pressure by pushing core of valve end in.

3472

4. Unscrew the filter in a counterclockwise direction to remove.

ob01253

FILTER DRAINING1. Slide filter holder up to release from bracket. Hoses and wire harness can remain

attached to filter holder.

Maintenance

Page 1B-12 90-896580100 JULY 2004

2. Tip the filter holder to drain any fluid into an approved container.

ob01263

FILTER INSTALLATION1. Position filter holder onto bracket and secure filter holder in place.2. Lubricate the sealing ring on the filter with oil.3. Install the filter and tighten securely by hand.IMPORTANT: Visually inspect for fuel leakage from the filter while turning the ignition keyto the run position, forcing fuel into the filter.

ob01258

Corrosion Control AnodeThe outboard has corrosion control anodes at different locations. An anode helps protectthe outboard against galvanic corrosion by sacrificing its metal to be slowly eroded insteadof the outboard metals.Each anode requires periodic inspection, especially in salt water which will accelerate theerosion. To maintain this corrosion protection, always replace the anode before it iscompletely eroded. Never paint or apply a protective coating on the anode as this willreduce effectiveness of the anode.

Maintenance

90-896580100 JULY 2004 Page 1B-13

Two anodes are located on each side of the gearcase. Another anode is installed on thebottom of the pedestal. Two more anodes are located on the bottom of each power trim ram.

ob01515

Propeller Replacement1. Shift outboard to neutral position.2. Straighten the bent tabs on the propeller nut retainer.

ob00376

3. Place a block of wood between gearcase and propeller to hold propeller and removepropeller nut.

ob01672

4. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed,have the propeller removed by an authorized dealer.

5. To aid in future removal of the propeller, liberally coat the propeller shaft splines withone of the following Mercury/Quicksilver products:

Tube Ref No. Description Where Used Part No.94 Anti-Corrosion Grease Propeller shaft splines 92-802867A195

2-4-C Marine Lubricant withTeflon Propeller shaft splines 92-802859A1

Maintenance

Page 1B-14 90-896580100 JULY 2004

6. Flo-Torq II Drive Hub Propellers - Install forward thrust hub, replaceable drive sleeve,propeller, thrust hub, propeller nut retainer and propeller nut onto the shaft.

b ca

d

fe

ob00421

a - Propeller nutb - Propeller nut retainerc - Thrust hub

d - Propellere - Replaceable drive sleevef - Forward thrust hub

7. Place a block of wood between gearcase and propeller and torque to specifications.Description Nm lb. in. lb. ft.Propeller nut 75 558. Secure propeller nut by bending three of the tabs into the thrust hub grooves.

ob00422

Spark Plug Inspection and Replacement1. Remove top and rear cowlings. Refer to Cowl Removal and Installation.2. Disconnect the six wiring harness connectors from pencil coil connections.3. Remove mounting bolts, using a twisting motion, and pull pencil coils from spark plugs.

a b

c

3658

a - Wiring harness connectorb - Pencil coil

c - Bolt

4. Remove the spark plugs to inspect. Replace spark plug if electrode is worn, threads ofseal area are corroded, or the insulator is rough, cracked, broken, blistered or fouled.

ob01092

Maintenance

90-896580100 JULY 2004 Page 1B-15

5. Set the spark plug gap to specifications.

ob00680

Spark Plug Spark Plug Gap 0.8 mm (0.0315 in.)6. Saltwater use - Apply a thin coating of Anti-Seize Compound only on threads of spark

plugs.7. Clean area of spark plug seat.8. Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs

finger tight, and then tighten 1/4 turn or torque to specifications.Description Nm lb. in. lb. ft.Spark plug 27 209. Push pencil coils into place over the spark plugs using a twisting motion.10. Secure coils with retained bolts. Torque to specifications.Description Nm lb. in. lb. ft.Bolts 8 7111. Connect the six wiring harness connectors to pencil coil connections.

a b

c

3658

a - Wiring harness connectorb - Pencil coil

c - Bolt

12. Reinstall rear and top cowls.Fuses

The electrical wiring circuits on the outboard are protected from overload by fuses in thewiring. If a fuse is blown, try to locate and correct the cause of the overload. If the causeis not found, the fuse may blow again.

Maintenance

Page 1B-16 90-896580100 JULY 2004

1. Remove top cowl. Locate fuse holder on starboard side of engine.

ob01516

2. Remove the plastic cover from the fuse holder.3. Remove fuse puller from fuse holder.4. Remove suspected blown fuse to determine if the silver colored band is broken.5. Replace fuse with a new fuse of the same amperage rating.

ob01252

ob01259

20 20 20

20 20 20

20

ab

c

d

ea - Electronic Control Module and

purge valve "ECM" - 20 amp fuseb - Ignition coils "IGN. COILS" - 20

amp fusec - Fuel delivery "FUEL" - 20 amp

fuse

d - Spare fuses - 20 amp fusee - Injector power and boost valve "INJ.

PWR." - 20 amp fuse

DTS Wiring System! WARNING

To avoid the possibility of serious injury or death from loss of boat control, do not spliceor probe into any wire insulation of the DTS system. Splicing or probing will damage thewire insulation allowing water to enter the wiring. Water intrusion may lead to wiring failureand loss of throttle and shift control.

Verify the harnesses are not routed near sharp edges, hot surfaces or moving parts.

Maintenance

90-896580100 JULY 2004 Page 1B-17

Verify that all unused connectors and receptacles are covered with a weather cap. Verify that the harnesses are fastened along the routing path.

Accessory Drive Belt InspectionInspect the accessory drive belt and have it replaced by an authorized dealer if any of thefollowing conditions are found. Cracks in the back of the belt or in the base of V grooves. Excessive wear at the roots of the groves. Rubber portion swollen by oil. Belt surfaces roughened. Signs of wear on edges or outer surfaces of belt.

Checking Power Trim Fluid1. Tilt outboard to the full up position.2. Rotate the tilt support bracket down.3. Lower outboard until tilt support bracket rests on pedestal.4. Remove the power trim fill cap. The fill cap only requires 1/4 turn to remove.

ob01526

a

d

b

c

a - Tilt support leverb - Power trim fill cap

c - Tilt support bracketd - Pedestal

5. The fluid level should be approximately 25 mm (1 in.) from the top of the fill neck. AddQuicksilver or Mercury Precision Lubricants Power Trim & Steering Fluid. If notavailable, use automotive automatic transmission fluid (ATF).

6. Reinstall the power trim fill cap. Tighten fill cap 1/4 turn. Cap will snap in place. Do nottighten beyond this point.

Maintenance

Page 1B-18 90-896580100 JULY 2004

Checking Power Steering FluidRemove power steering cover and fill cap to check fluid level. The fluid level should beslightly below the bottom of the fill hole. Use SAE 0W-30 synthetic power steering fluid, ifneeded.

ob01527

ab

c

a - Power steering coverb - Fill cap

c - Fill/full level

Changing Engine OilEngine Oil Capacity

Engine oil capacity is approximately 7.0 liters (7.4 quarts)Pump Method

IMPORTANT: Tilt outboard out/up past vertical for approximately one minute to allowtrapped oil to drain back to the oil sump.IMPORTANT: To reduce or prevent oil spillage when removing the oil filter, make sure thatthe outboard is upright (not tilted) and the engine is cold or has not run for at least one hour.IMPORTANT: The pump method is preferred to remove engine oil from XXL models. If thedrain method is used, an oil drain deflector tool must be used to divert oil from the lowersplash plate and into the container.1. Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to

drain back to the oil sump.2. Place the outboard in a vertical position.3. Remove dipstick and slide adaptor tube of crankcase oil pump through oil dipstick hole,

to bottom of engine oil sump.4. Pump out the engine oil into an appropriate container.Crankcase Oil Pump 91-90265A5

Drain Method1. Tilt outboard out/up past vertical for approximately one minute to allow trapped oil to

drain back to the oil sump.2. Place the outboard in a vertical position.3. Place appropriate container under engine oil sump plug. Drain plug/seal washer is

located beneath the splash plate (port side of outboard).

Maintenance

90-896580100 JULY 2004 Page 1B-19

4. Loosen drain plug/seal washer and install optional oil drain funnel over drain plug/sealwasher and slide tool onto splash plate.

ob01264

a

b

a - Drain plug/seal washer b - Oil drain funnel

Oil Drain Funnel 91-892866A015. Remove drain plug/seal washer and drain engine oil into container.6. Reinstall drain plug/seal washer.

Changing Oil FilterIMPORTANT: To reduce or prevent oil spillage when removing the oil filter ensure that theoutboard is upright (not tilted) and the engine is cold or has not run for at least one hour.1. Remove the top cowl.2. Place a rag or towel below the oil filter to absorb any spilled oil.3. Unscrew old filter by using oil filter wrench tool and turning the filter counterclockwise.

ob01251

Oil Filter Wrench 91-8952770014. Clean the oil filter mounting base.5. Apply film of clean oil to filter gasket. Do not use grease.6. Screw new filter on until gasket contacts base, then tighten 3/4 to 1 turn.

Maintenance

Page 1B-20 90-896580100 JULY 2004

Oil Filling1. Remove the oil fill cap and add recommended oil to the mid point of the operating range

(mid point of cross hatched region). Adding approximately 7 liters (7.4 quarts) will bringoil level to mid point of cross hatched region.

ob01250

2. Reinstall oil fill cap.3. With outboard in water or cooling water flush hose connected, idle engine for five

minutes to check for leaks at the oil filter.4. Stop engine and check oil level.

Storage PreparationThe 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 ofseason storage or prolonged storage (two months or longer).

! CAUTIONNever start or operate your outboard (even momentarily) without water circulatingthrough all the cooling water intake holes in the gearcase to prevent damage to the waterpump (running dry) or overheating of the engine.

Fuel SystemIMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation ofacid during storage and can damage the fuel system. If the gasoline being used containsalcohol, it is advisable to drain as much of the remaining gasoline as possible from the fueltank, remote fuel line, and engine fuel system.IMPORTANT: This outboard is equipped with a closed fuel system when the engine is notrunning. With this closed system, fuel within the engine's fuel system, other than the fueltank, will remain stable during normal storage periods without the addition of fuel treatmentstabilizers.Fill the fuel tank and engine fuel system with treated (stabilized) fuel to help preventformation of varnish and gum. Proceed with following instructions. Portable Fuel Tank - Pour the required amount of gasoline 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 gasoline stabilizer

(follow instructions on container) into a separate container and mix with approximatelyone quart (one liter) of gasoline. Pour this mixture into fuel tank.

Maintenance

90-896580100 JULY 2004 Page 1B-21

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).Protecting Internal Engine Components

IMPORTANT: Refer to Maintenance - Spark Plug Inspection and Replacement for correctprocedure for removing spark plugs. Remove pencil coils and spark plugs. Spray approximately 30 ml (1 fl. oz.) of Storage Seal Rust Inhibitor into each spark plug

hole. Actuate key/push button start switch to crank the engine through one start cycle, which

will distribute the storage seal throughout the cylinders. Reinstall spark plugs and pencil coils.

Gearcase Drain and refill the gearcase lubricant (refer to Maintenance - Gearcase Lubrication).

Positioning Outboard For StorageStore outboard in an upright (vertical) position to allow water to drain out of outboard.

! CAUTIONIf outboard is stored tilted up in freezing temperature, trapped cooling water or rain waterthat may have entered the propeller exhaust outlet in the gearcase could freeze andcause damage to the outboard.

Battery Storage Follow the battery manufacturer's instructions for storage and recharging. Remove the battery from the boat and check water level. Recharge if necessary. Store the battery in a cool, dry place. Periodically check the water level and recharge the battery during storage.

Gearcase LubricationWhen adding or changing gearcase lubricant, visually check for the presence of water inthe lubricant. If water is present, it may have settled to the bottom and will drain out priorto 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 mayresult in premature bearing failure or, in freezing temperatures, will turn to ice and damagethe gearcase.Examine the drained gearcase lubricant for metal particles. A small amount of metalparticles indicates normal gear wear. An excessive amount of metal filings or largerparticles (chips) may indicate abnormal gear wear and should be checked by an authorizeddealer.

Draining Gearcase1. Place outboard in a vertical operating position.

Maintenance

Page 1B-22 90-896580100 JULY 2004

2. Remove propeller. Refer to Propeller Replacement.3. Place drain pan below outboard.4. Remove vent plug and fill/drain plug and drain lubricant.

ob01529

a

b

a - Vent plug b - Fill/drain plugGearcase Lubricant Capacity

Gearcase lubricant capacity is approximately 970 ml (32.8 fl. oz.).Gearcase Lubricant Recommendation

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

1. Place outboard in a vertical operating position.2. Remove vent plug/sealing washer.3. Remove fill/drain plug. Place lubricant tube into the fill hole and add lubricant until it

appears at the vent hole.

aob01530

a

b

a - Vent hole b - Fill holeIMPORTANT: Replace sealing washers if damaged.4. Stop adding lubricant. Install the vent plug and sealing washer before removing the

lubricant tube.5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer.

Submerged OutboardA submerged outboard will require service within a few hours by an authorized dealer oncethe outboard is recovered from the water. This immediate attention by a servicing dealeris necessary once the engine is exposed to the atmosphere to minimize internal corrosiondamage to the engine.

General Information

90-896580100 JULY 2004 Page 1C-1

1CImportant Information

Section 1C - General InformationTable of ContentsSerial Number Location...................................1C-2Model Year 2005 Verado Powerhead Front View.........................................................................1C-3Model Year 2005 Verado Powerhead StarboardView.................................................................1C-4Model Year 2005 Verado Powerhead Port View.........................................................................1C-6Model Year 2005 Verado Powerhead Aft View.........................................................................1C-8Model Year 2005 Verado Powerhead Top View.........................................................................1C-9Conditions Affecting Performance...................1C-9

Weather....................................................1C-9Weight Distribution (Passengers and Gear)Inside the Boat........................................1C-10Bottom of Boat .......................................1C-10Water Absorption....................................1C-11Cavitation................................................1C-11Ventilation...............................................1C-11Detonation..............................................1C-11

Following Complete Engine Submersion.......1C-12

Engine Submerged While Running (SpecialInstructions)............................................1C-12Fresh Water Submersion (SpecialInstructions)............................................1C-12Salt Water Submersion (Special Instructions)................................................................1C-12

Power Trim System.......................................1C-13Power Trim and Tilt................................1C-13Power Trim Operation............................1C-13Tilting To Full Up Position.......................1C-14Manual Tilting.........................................1C-15Auxiliary Tilt Switch.................................1C-15Shallow Water Operation........................1C-16

Compression Check......................................1C-16Cylinder Leakage Testing..............................1C-17

Analysis..................................................1C-17Painting Procedures......................................1C-18

Propellers...............................................1C-18Gear Housing.........................................1C-18

Decal Removal..............................................1C-19Decal Application...........................................1C-19

General Information

Page 1C-2 90-896580100 JULY 2004

Serial Number LocationThe serial number of the engine is located on the starboard side of the pedestal.

S ee rrial Numb

MAXRPM

HPLB

KWKG

20XX

XX

OTXXXXXX

XXXX

a

b

c

ed

ob01322

a - Serial numberb - Model yearc - Model designation

d - Year manufacturede - Certified Europe Insignia (as

applicable)

General Information

90-896580100 JULY 2004 Page 1C-3

Model Year 2005 Verado Powerhead Front View

1

2

34

5

6

7

8

9

10

11 12

13

16

17

014

1155005

1 - 14 pin engine harness connector2 - Shift position indicator harness3 - Resonator4 - Oil filter5 - Fuel filter6 - Air filter7 - Supercharger8 - Alternator9 - Electronic Boost Control (EBC)

Assembly

10 - Speedometer sensor11 - Fresh water flush hose12 - Cowl mounted tilt switch13 - Electronic Shift Control (ESC)

Assembly14 - Steering cylinder bleed port15 - Steering cylinder hydraulic fittings16 - Electronic Throttle Control (ETC)

Assembly17 - Supercharger boost air

temperature sensor

General Information

Page 1C-4 90-896580100 JULY 2004

MODEL YEAR 2005 VERADO POWERHEAD STARBOARD VIEW

1

2

3

4

5

6

7

8

9

10

11

12

131415

161718

19

20

21

22

23

24

25

26

27

28

29

30

31 32

33

34

35

36

37

38

5010

General Information

90-896580100 JULY 2004 Page 1C-5

1 - Thermostat housing2 - Oil pressure sensor3 - Oil temperature sensor4 - Integrated Oil Module (IOM)5 - Fuel line to Fuel System Module6 - Air filter7 - Oil filter8 - Resonator9 - Power steering signal harness connector10 - Shift indicator switch11 - Fuel line (Fuel in)12 - Tilt lock lever13 - Battery cable (Positive)14 - 14 pin engine harness connector15 - DTS power harness16 - Boat sensor harness17 - Battery cable (Ground)18 - Fuel System Module (FSM) harness connector19 - Splicesaver (red / yellow)20 - Trim wire harness connector21 - Splicesaver (red / orange)22 - PCM23 - Relay, starter24 - Relay, Main power25 - Relay, Trim down26 - Relay, Trim up27 - Diagnostic port (4 pin)28 - Fuses29 - Fuseable link, 150 Amp30 - Cylinder head temperature sensor31 - Vent Canister Purge Valve (VCPV)32 - Crank Position Sensor (CPS)33 - FSM purge valve34 - Hot stud (battery positive)35 - Vent Canister Float Switch (VCFS)36 - Fuel filter (2 micron)37 - CAN terminating resistor38 - Water separating sensor

General Information

Page 1C-6 90-896580100 JULY 2004

MODEL YEAR 2005 VERADO POWERHEAD PORT VIEW

1 2 3

4

5

6

7

89

1011

12

13

141516

17

18

25

1920

21

22 23

24

5014

General Information

90-896580100 JULY 2004 Page 1C-7

1 - Alternator2 - Charge Air Cooler (CAC)3 - Manifold Absolute Pressure (MAP) sensor4 - Fuel pressure port5 - Fuel rail6 - Manifold Air Temperature (MAT) sensor7 - Cylinder block water pressure sensor8 - Trim position sensor harness connector9 - Fuel inlet line to fuel rail10 - MAP reference line to FSM11 - Fuel filter (20 micron)12 - Lower knock sensor harness connector (with black sleeve)13 - Trim position senor14 - Tilt lock lever15 - Tilt switch16 - Fresh water flush inlet17 - Fresh water flush hose18 - Tilt switch harness connector19 - Upper knock sensor harness connector20 - Electronic Throttle Control (ETC) Assembly21 - Speedometer sensor22 - Electronic Boost Control (EBC)23 - Oil dipstick24 - Electronic Shift Control (ESC) harness connector25 - Supercharger

General Information

Page 1C-8 90-896580100 JULY 2004

Model Year 2005 Verado Powerhead Aft View

1

2

3

4

5

6

7

89

1011

12

13

14

15

17

16 50171 - Block water pressure sensor2 - Manifold Air Temperature (MAT)

sensor3 - Fuel rail4 - Intake manifold5 - Cam position sensor6 - Manifold Absolute Pressure

(MAP) sensor7 - Oil fill plug8 - Fuseable link, 150 amp9 - FSM purge valve

10 - Diagnostic port (4 pin)11 - Fuse holder12 - Fuse puller13 - Pencil coil14 - Plenum15 - Motor mount, rear16 - FSM protection cover17 - Exhaust relief

General Information

90-896580100 JULY 2004 Page 1C-9

Model Year 2005 Verado Powerhead Top View

1

2

3 45

6

7

8

9 10

111213

1415

16

5018

1 - Oil fill plug2 - Cylinder block water temperature

sensor3 - Manifold Absolute Temperature

(MAP) sensor4 - Charge Air Cooler5 - Alternator6 - Belt Tensioner7 - Supercharger8 - Oil pressure sensor

9 - Crank Position Sensor (CPS)10 - Vent canister purge valve hose11 - Air filter12 - Breather hose13 - Integrated Oil Module (IOM)14 - Starter15 - Fuse holder16 - Thermostat housing

Conditions Affecting PerformanceWeather

It is a known fact that weather conditions exert a profound effect on the power output ofinternal combustion engines. Therefore, established horsepower ratings refer to the powerthat the engine will produce at its rated RPM under a specific combination of weatherconditions.Corporations internationally have settled on adoption of I.S.O. (International StandardsOrganization) engine test standards, as set forth in I.S.O. 3046 standardizing thecomputation of horsepower from data obtained on the dynamometer. All values arecorrected to the power that 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.

General Information

Page 1C-10 90-896580100 JULY 2004

Summer conditions of high temperature, low barometric pressure and high humidity allcombine to reduce the engine power. This in turn is reflected in decreased boat speeds asmuch as 3 to 5 km/h (2 to 3 MPH) in some cases. Nothing will regain this speed for theboater but cooler, dry weather.Pointing out the consequences of weather effects, an engine running on a hot humid daymay 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 uponthe density of the air that it consumes. The density of air is dependent upon the ambientair temperature, the barometric pressure and the humidity (water vapor) content.Accompanying the effects of weather inspired loss of power is a second but more subtleloss. Consider a boat rigged during cooler, less humid weather with a propeller that allowedthe engine to turn within its recommended RPM range at full throttle. Higher temperatureswith high humidity weather will consequently decrease the available horsepower. Thepropeller in effect is too large for the atmospheric conditions. Consequently the engineoperates at less than its recommended RPM.The engine rated horsepower is a direct relation to the engines' RPM. An engine with toolarge a propeller will have a further loss of horsepower and subsequent decrease in boatspeed. This secondary loss of RPM and boat speed can be regained by switching to asmaller pitch propeller that allows the engine to run at recommended RPM.For boaters to realize optimum engine performance under changing weather conditions, itis essential that the engine have the proper propeller to allow it to operate at or near thetop end of the recommended maximum RPM range at wide-open-throttle with a normalboat load. Not only does this allow the engine to develop full power, but equally important,is the engine will be operating in an RPM range that discourages damaging detonation.This of course enhances overall reliability and durability of the engine.

Weight Distribution (Passengers and Gear) Inside the BoatShifting 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 porpoiseShifting 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 BoatFor maximum speed, a boat bottom should be nearly a flat plane where it contacts thewater 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 allowsbow to drop, thus greatly increasing wetted surface and reducing boat speed. Hookfrequently is caused by supporting boat too far ahead of transom while hauling on atrailer or during storage.

Rocker: The reverse of hook and much less common. Rocker exists if bottom is convexin fore and aft direction when viewed from the side, and boat has strong tendency toporpoise.

Surface Roughness: Moss, barnacles, etc., on boat or corrosion of outboards gearhousing increase skin friction and cause speed loss. Clean surfaces when necessary.

General Information

90-896580100 JULY 2004 Page 1C-11

Water AbsorptionIt is imperative that all through hull fasteners be coated with a quality marine sealer at timeof installation. Water intrusion into the transom core and/or inner hull will result in additionalboat weight (reduced boat performance), hull decay and eventual structural failure.

CavitationCavitation occurs when water flow cannot follow the contour of a fast-moving underwaterobject, such as a gear housing or a propeller. Cavitation permits the propeller to speed up,but the boat speed to reduce. Cavitation can seriously erode the surface of the gear housingor 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

VentilationVentilation is caused by surface air or exhaust gases that are introduced around thepropeller resulting in propeller speed-up and a reduction in boat speed. Air bubbles strikethe propeller blade and cause erosion of the blade surface. If allowed to continue, eventualblade 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.

DetonationDetonation in a 4-cycle engine resembles the pinging heard in an automobile engine. Itcan 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 orcreate a weakness: the dome of a piston, cylinder head or gasket, piston rings or pistonring lands, piston pin and roller bearings.A few of the most common causes of detonation in a marine 4-cycle application are asfollows: Over-advanced ignition timing. Use of low octane gasoline. Propeller pitch too high: engine RPM below recommended maximum range. Lean fuel mixture at or near wide open throttle. Spark plugs: heat range too hot, incorrect reach, cross-firing. Deteriorated or inadequate engine cooling system. Combustion chamber deposits: result in higher compression ratio.Detonation usually can be prevented if: The engine is correctly set up. Regular maintenance is scheduled.

General Information

Page 1C-12 90-896580100 JULY 2004

Following Complete Engine SubmersionEngine Submerged While Running (Special Instructions)

When an engine is submerged while running, the possibility of internal engine damage isgreatly increased. After the engine is recovered, remove the spark plugs. If the engine failsto turn over freely when turning the flywheel, the possibility of internal damage (bentconnecting rod and/or bent crankshaft) exists. The powerhead must be disassembled forinspection.

Fresh Water Submersion (Special Instructions)1. Recover the engine as quickly as possible.2. Place engine at full trim in.3. Remove cowling.4. Flush exterior of outboard with fresh water to remove mud, weeds, etc. Do not attempt

to start engine if sand has entered powerhead. Disassemble powerhead if necessaryto clean components.

5. Remove spark plugs and get as much water as possible out of powerhead. Most of thewater inside the combustion chambers, can be eliminated by rotating the flywheel whilethe engine is tilted in.

6. Remove the rubber boot from the ETC assembly. Drain water from the rubber boot.7. Remove spark plugs and pour approximately one teaspoon of engine oil into each spark

plug opening. Rotate flywheel to distribute oil in cylinders.8. Change the engine oil. Run the outboard for 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.9. Dry all wiring and electrical components using compressed air.10. Disassemble the engine starter motor and dry all the internal parts with compressed

air. Be careful not to loose the brush springs.11. Reinstall spark plugs.12. Attempt to start engine, using a fresh fuel source. If engine starts, it should be run for

at least one hour to eliminate any water in engine. Run the outboard for short time andcheck for the presence of water in the oil. If water is present, the oil will appear milky.Drain and replace the oil as previously mentioned.

NOTE: The fuel system is closed to the ambient air at all times when the engine is notrunning.13. If engine fails to start, determine if the cause is fuel, electrical or mechanical. The engine

should be run within 2 hours after recovery from the water, or serious internal damagewill occur. If unable to start engine within 2 hours of recovery, disassemble the engineand clean all parts. Apply oil as soon as possible.

Salt Water Submersion (Special Instructions)Due to the corrosive effect of salt water on internal engine components, completedisassembly of the engine is necessary before any attem

151463852-200-through-to-275hp-verado

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