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BOAT MAINTENANCE .. . . . •• . . ••• . . •••. 2·28 BATIERIES . . . . . . . . . . 2·28 MAINTENANCE. 2·28 STORAGE. . . . 2·29 TESTING. . . .. . . . .. . . . .• 2·29 FIBERGlASS HULL. 2·30 INTERIOR... .. ... ...... .. .. ..... .. .. 2-30 CLEARING ASUBMERGED MOTOR •••..•• 2·77 ENGINE MAINTENANCE .. .• . •• . . . •• . . •• 2·9 AIR FILTER.. ......... .... .. 2·26 REMOVAL & INSTALLATION . 2·26 ANODES (ZINCS). . . . 2·23 INSPECTION. . . . . . . . . . . . . 2·24 SERVICING. . . . . . . . . . .. 2·24 COOLING SYSTEM . • . 2·9 FLUSHING JET DRIVES.. .... .... ... 2·11 FLUSHING THE SYSTEM . 2·9 DRIVE BELT. . . . . . . .. . . . 2·24 INSPECTION. . . . . . . . . . . . . •. 2·24 REMOVAL & INSTALLATION ........... 2·25 ENGINE COVERS. . . . . .. . . . . 2·9 REMOVAL & INSTALLATION . . . . . . 2·9 FUELFILTERIFUEL WATER SEPARATOR. 2·12 RELEASING PRESSURE. ..... 2·13 SERViCE............•............. 2·14 JET DRIVE IMPELLER. . . . . . . . . . . . . 2·22 IMPELLER CLEARANCE .. . 2·22 INSPECTION . 2·22 OIL FILTER. . .. . . . . . . . . . . . . . . . . . . • . . 2·27 REMOVAL & INSTALLATION. . . 2·27 PROPELLER. . . ................ 2·16 GENERAL INFORMATION . .. . .. ...... 2·1 6 INSPECTION .... . .. ... .. 2·1 8 REMOVAL & INSTALLATION . 2·18 2·STROKE OIL. . . . . . . . . •. . 2·12 FILLING......... . ..... 2·12 OIL RECOMMENDATIONS .. .. .. .. 2·12 GENERAL INFORMATION •• . . ••• . ••. . . .. 2·2 BEFOREfAFTER EACH USE 2·2 ENGINE IDENTIFICATION. . . . . . . . . 2·2 MAINTENANCE COVERAGE . . . • . . . . . 2·2 MAINTENANCE EQUALS SAFETY. . . . . . . . 2·2 OUTBOARDS ON SAIL BQATS. . •• . . . . . .. 2·2 LUBRiCATION. ... . ••• . . ••• . . •••• ••• . . 2-4 ABOUT LUBRICATION . . 2·4 JET DRIVE BEARING . . . 2·8 LOWER UNIT. . . . . . . . . . . . . . . . . 2-4 LUBRICATION INSIDE THE BOAT . . . . 2·4 LUBRICATING THE MOTOR.. ..... ...... 2·4 POWER TRIMITILT RESERVOIR 2-9 STORAGE. . ••• . . ••• . ••.. . .... . 2·73 PREPPING FOR STORAGE ... 2·74 RE-COMMISSIONING. . ........ 2·76 REMOVAL FROMSTORAGE. 2·76 WINTERIZATION ... . . . . . . . . . . . . . . . . .. 2·73 TIMING AND SyNCHRONiZATION •• .. ••• . • 2·40 2.513.3 HP MODELS .... .. ... . ... 2·41 IDLE SPEED . 2·41 IGNITION TIMING. 2·41 THROmE JET NEEDLE.. 2-41 415 HP MODELS. . . . . . • . . . . . . . . . . 2·42 IDLE SPEED & MIXTURE .......... 2·43 IGNITION TIMING . . . .. 2·42 618 &9.911 0115 HP MODELS 2-43 IDLE SPEED ..... 2·43 IDLE WIRE .. . . ........ 2·45 IGNITION TIMING. . . . . . . . . . . . . . . 2-44 LOW SPEED MIXTURE. .. . . . . . . . • . . . 2-43 20120 JET/25 HP MODELS. . . . . 2·45 CARBURETOR & LINKAGE . . .. 2-45 IDLE SPEED & MIXTURE. . . . . . . . . . . 2·47 IGNITION TIMING. . . . . . . . . . . . . . . . 2-47 30140 HP CYL MODELS. . . . . 2-47 IDLE SPEED & MIXTURE .......... 2·48 IGNITION TIMING 2·49 OIL PUMP ......................... 2·50 REMOTE CONTROL CABLE.. . . . . . 2·48 4I}-125 HPCAAElJRETEDJ..tW4-CYLt.OES . 2·50 IDLE SPEED. . . . . . . . . . . . . . 2·52 IGNITION TIMING. .. .. .•...•. 2·51 SYNCHRONtZATION. . . . . . . . . . 2·50 75190/115 HP OPTIMAX MODELS 2·53 THRomE LINKAGE ADJUSTMENT . . 2·53 150·200 HP (2.5L) V6 CARB MODELS. 2·53 IDLE SPEED. . . . . . .. . . . . . . . . . 2·56 IGNITIONTIMING . . .. . . . .. . . . • . 2·55 SYNCHRONIZATION . . . . . 2·54 TIMING POINTER ADJUST . . . .. ... 2·53 150·200 HP (2.5L) V6 EFI· 2001 2,57 DYNAMIC IDLE TIMING... .. .. . .. 2·60 DYNAMIC MAX TIMING.. . 2·61 IDLE SPEED. . . . . . . . . . . ....... 2·60 MAXIMUM THROmE .•. 2·59 STATIC IDLE TIMING............. 2·58 STATIC MAX TIMING.. ....... 2·58 THROmE CABLE PRELOAD . . 2·61 THROmE CAM. . . . . . . . . . . . . 2·58 THROmE POSITION SENSOR.. 2·59 THROmE VALVE & OIL PUMP SYNCH .. 2·61 TIMER POINTER. . . . . . . . . . 2·57 TRIGGER LINK ROD. . . . . . . . . . • 2·57 150·200 HP (2.5L) V6 EFI· 2002·05 . 2,61 IDLE SPEED . . . . 2·62 IGNITION TIMING . . . . . . . . • . 2·62 MAXIMUM THRomE •....•. 2·62 THROTILE CABLE INSTALl. . . 2·63 THRomE CAM. . . . . . . . . . . . . . . 2·62 nmOTILE PLATE SCREW. . . . 2-64 THROmE POSITION SENSOR. . . . . 2·62 135·175 HP (2.5L) V6 OPTIMAX. . . . . 2-64 IDLE SPEED. . . . . . . . . . . . . . . . . . . . . 2·65 MAXIMUM nmomE .. . . . . . . . . . 2·64 THRomE CAM. . . . . . . . . . . . 2·64 THROmE PLATE SCREW.. ... 2-65 THROmE POSITION SENSOR.. 2-65 225·250 HP (3.0L) V6 EFI . 2001 .•. 2-65 CRANKSHAFT POSITION SENSOR. .. . 2·66 IDLE SPEED. . . . . . . . . . . . . . . . . . . . . . 2·68 MAXIMUM THRomE .... . . . . . . . . .. 2·66 THRomE CAM. . . . . . . . . . . . . . 2·66 THRomE POSITION SENSOR. 2·67 THROTILE VALVE &OIL PUMP SYNCH.. 2-66 TIMER POINTER. . . . . . . . . . . . . . . . 2·66 200,250 HP (3.0LJV6 EFt -2002·05 ....... 2·68 IDLE SPEED ••...•...•.... •.......• 2·69 IGNITION TIMING. . . 2-69 MAXIMUM THRomE 2·69 THRomE CABLE. . . . . . . . . . . . . . . . . 2·69 THROTTLE CAM. . . . . . . . . . . . . . 2·68 THROmE PLATE SCREW.. .... 2·70 THROTtlE POSITION SENSOR . . . 2·69 200·225 HP (3.0L) V6 OPTIMAX. . . . . 2·70 CRANKSHAFT POSITION SENSOR 2·70 IDLE SPEED . . .. 2·73 MAXIMUM THRomE 2·71 THROmE CAM. . . . . .. . . . . 2-70 THROmE PLATE SCREW. ... . . •. 2·73 THRomE POSITION SENSOR. 2·73 TUNE·UP ••• . . ••• . . •• . . •• . . ••. . •• 2·31 COMPRESSION TESTING . . . . . . . . . 2·32 COMPRESSION CHECK. • . . . • . . . 2·32 LEAK TESTING . . 2·33 LOW COMPRESSION. . . . . . . . . . . .. . 2·33 ELECTRICAL SYSTEM CHECKS . 2·39 FUEL SYSTEM CHECKS. . . . . . . . . . . . . 2·40 IGNITION SYSTEM. 2-38 INTRODUCTION..... 2·31 SPARK PLUG WIRES . 2·38 REMOVAL & INSTALLATiON. 2-38 TESTING. . . . . . . . . . 2,38 SPARK PLUGS . 2·34 HEAT RANGE. . . . . . . . . . . . .• . . 2·34 INSPECTION &GAPPING. 2·38 READING SPARK PLUGS . . 2·36 REMOVAL & INSTALLATION. 2·35 TUNE·UP SEQUENCE........... 2·31 SPECiFiCATiONS •• ... ••..••..••..•• . •• 2·79 GENERALENGINE (2.5·125 HPj... 2·79 GENERAL ENGINE (135·250 HP). . . . . • . .. 2·80 MAINTENANCE INTERVALS ..... .... 2·S1 TWO·STROKE MOTOR FUEL:OIL RATIO.. 2-82 CAPACITIES. .. . . . . . . . . . . . . . . . . . . . 2·82 TUNE·UP (2.5·125 HP). 2·83 TUNE-UP (135-250 HPJ. . . . . . . . . . . 2·84 CARBURETEDFUEL SySTEM ............ 3-12 DESCRIPTION AND OPERATION .. 3-12 BASIC FUNCTIONS 3-13 CiRCUiTS.......... . ... 3·13 FUEL PUMP FUNCTK)NS. ... .......... 3·14 GENERAL INFORMATION . 3-12 ENRICHENER SYSTEMS. HI DESCRIPTION &OPERATION. 341 PRIMER HOSE ROUTING DIAGRAMS.. 3-42 TESTING . . . . . . . . . . 341 THERMAL AIR VALVE CIRCUIT 344 fUEL PUMP ......... ................ 3·37 OVERHAUL . 3·39 REMOVAL &INSTALlATION. .... 3.J8 TESTING . . . . . .... ...... 3·37 TROUBLESHOOTING . 3-14 COMMON PROBLEMS ... .......... 3-16 LOGICAL TROUBLESHOOTING.. 3·15 2.513.3 HP ..............• 3-17 CLEANING & INSPECTION . 3·20 OVERHAUL.... . ........... 3·1 8 REMOVAL & INSTALLATlON. 3·17 415 HP . .•. 3·20 CLEANING & INSPECTION . . . . . . . . . ... 3·21 OVERHAUL .. . . . . . . . . . . . . . . . . . 3·21 REMOVAL& INSTALlATION. . . . . . .... 3·20 6/8,9.911011 5 &20120 JETI25 HP. 3-24 CLEANING & INSPECTION 3·26 OVERHAUL. . . . . . . . 3-24 REMOVAL & INSTALLATION. . 3-24 30140 HP gYl. . . . . . . . . . . 3-28 CLEANING & INSPECTION . 3-30 OVERHAUL . . . . . . .... .. . 3-29 REMOVAL & INSTALLATION. . 3-28 4(}.125 HP AND 4-CYL. . . 3·31 OVERHAUL 3~2 REMOVAL & INSTALLATlON. . . . . 3·31 1501200 HP (2.5L) V6. .. ............ .... 3-33 CLEANING & INSPECTION 3-36 OVERHAUL. . . . . . . . . . . . . . . . . . ...... 3-34 REMOVAL &INSTALLATION............ 3·33 ELECTRONICfUEL INJECTION (EFI)....... 3-44 AIR TEMPERATURE SENSOR.. J.57 DESCRIPTION &OPERATION . J.57 REMOVAL & INSTALLATION. . 3-57 TESTING . . . . . . .... 3·57 CRANKSHAFT POSITION SENSOR 3·60 DESCRIPTION AND OPERATION. 3-44 FUEL INJECTION BASICS . . . . 3-44 MERCURY Efl . 3-44 ELECTRIC FUEL PUMP. . 3·67 DESCRIPTION & OPERATION . 3--67 REMOVAL &INSTALLATION. . . . . . .• .••• 3·68 TESTING. ... .... ....... .... .. 3-67 ELECTRONIC CONTROl MODULE (ECM) . 3·62 DESCRIPTION &OPERATION. . . J.62 REMOVAL & INSTALLATION. . . . . . . . . . . J.63 ENGINE TEMPERATURE SENSORS. . 3·55 DESCRIPTION &OPERATION. 3·55 REMOVAL& INSTALLATION. . 3-57 TESTING .... ••. 3·55 FUEL INJECTORS, FUEL RAIL AND INTAKE MANIFOLD. 3-47 CLEANING & INSPECTION 3·55 DESCRIPTION &OPERATION . 3-47 REMOVAl & INSTALLATION. . 3·48 TESTING THE INJECTORS.... . 347 FUEL PRESSURE REGULATOR . 3-72 DESCRIPTION &OPERATION. 3-72 REMOVAL & INSTALlATION. . 3-72 TESTING. . . . ..... J..72 KNOCK SENSOR AND MODULE.. 3--61 DESCRIPTION &OPERATION. 3-61 TESTING . 3-61 MAP SENSOR. H8 DESCRIPTION &OPERATION 3·58 REMOVAL & INSTALLATION. . 3·59 TESTING . . . . . . . . . . . . . . . . . . .. ... . .. 3·59 MECHANICAL FUEL PUMP . 3--63 DESCRIPTION &OPERATION . 3--63 OVERHAUL. . . . . . . . .. .. ... 3-66 REMOVAL & INSTALLATION. . J.66 TESTING . J.64 THROmE POSITION SENSOR . 3-60 DESCRIPTION &OPERATION. 3-60 REMOVAL & INSTALLATION. ........... 3·61 TESTING. . . . . . . . . . . ....• .......... 3·60 TROUBLESHOOTING ........ .•. '. •. 3--4S BASIC DiAGNCSJS &PRBJMINARYTESTS... 345 COMPONENT TESTING . ..... 3-47 SELF·DIAGNOSTIC SYSTEM. 3-46 VAPOR SEPARATOR TANK [VSTj. H8 DESCRIPTION & OPERATION. 3-68 OVERHAUL. . . . . . . . . . . . . . . 3-70 REMOVAL &INSTALLATION. . 3-68 WATER SENSOR................... 3-62 DESCRIF'OON, CffAATl'JN &TESTltKi... :HI2 fUEL AND COMBUSTION BASiCS......... 3-2 CAUTIONS. . . . . . . . . . .. ..• . 3·2 COMBUSTION. . . . . . . . . . .............. 3-6 ABNORMAL ... . ........... 3-S FACTORS AFFECTING.. 3·6 PISTON FAILURES. ........ .......... H FUEL.......... ............. 3·2 SYSTEM PRESSURIZATION... . J.4 PRESSURIZING THE FUEL SYSTEM. . J.5 RELEASING PRESSURE (EAOPTlMAX). . . . 3-5 FUEL TANK AND LINES. 3-7 FUEL LINES & FITTINGS. . 3·9 SERVICE 3·9 TESTING . 3·9 FUEL TANK . . . . . . . . . . . . . . . . . . J.7 SERVICE. . . . . . . . . . . . . . . . . .. . . . .. . 3-7 OPTIMAX DIRECT FUEL INJECTION (OFI)... 3-73 AIR COMPRESSOR............... 3·n AIR/FUEL PRESSURE TESTING J.17 OVERHAUL . . . . . . .. .. ......... 3·82 REMOVAL& INSTALLATION. .. 3·78 AIR PRESSURE REGULATOR. 3·84 REMOVAl & INSTALLATION. . 3·85 TESTING ........ 3·84 CRANKSHAFT POSITION SENSOR. 3-88 DIRECT INJECTOR. . . . 3-92 REMOVAL& INSTALLATION. . 3·92 TESTING . . 3·92 ELECTRIC FUEL PUMP . . 3·99 REMOVAL & INSTALLAlK)N............ 3-100 TESTING. . . . . . . . . . . . . . . . . 3·99 ELECTRONIC CONTROL MODULE.. .. 3·91 DESCRIPTION &OPERATION. 3-91 REMOVAL & INSTALLATION............ J.91 FUEL (AND AIR) RAIL ...... . .. 3·101 REMOVAL & INSTALLATION. . . ... 3·101 fUEL INJECTOR ... 3·93 REMOVAL & INSTAlLATION.. 3·93 TESTING ... . . .. . 3-93 fUEL PRESSURE REGULATOR. 3-94 REMOVAL& INSTALLATION.. 3-94 TESTING . . . . . . . . . . . . . . . . . . . . . . . . .. 3·94 MAP SENSOR. . . . . . . . . . . . . . . . . . . . . . 3·90 REMOVAL & INSTALLAlK)N. J.90 TESTING. . .. . .. .. .. .... 3·90 MECHANICAL fUEL PUMP .... 3·95 OVERHAUL. .•. .. .......... 3·98 REMOVAL & INSTALLATION. .. . . ... ... 3·98 TESTING ............ 3--96 SHIFT INTERRUPT SWITCH . 3·90 REMOVAL & INSTAlLATlON.... ... .. ... 3-90 TESTING ............ ........... ... 3-90 TEMPERATURE SENSORS.. 3-86 REMOVAL & INSTALLATION. . 3-87 TESTING . . . . . 3·86 THROTILE POSITION SENSOR. 3.s8 REMOVAL & INSTALLATION. . H9 TESTING. . . . . . . . . . .............. 3.ss TRACKER VALVE ..•.••..••..••.•..... 3-1 02 REMOVAL& INSTALLATION............ 3-103 TROUBLESHOOTING .................. 3·75 !!ASIC DIAGNOSIS &PRELIMINARY TESTS... 3-75 COMPONENTTESTING . . . 3·n SELF·DIAGNOSTIC SYSTEM. 3-76 TESTING WID DDT . 3-76 TESTING WIDDT . 3-76 VAPOR SEPARATOR. 3·103 OVERHAUL ........................ 3·104 REMOVAL & INSTAlLATION ........ .. .. 3·103 SPEC1ACATIONS ..•.•••••••••••••••••• 3--107 CARBURETOR SEl-UP. .. 3-107 Efl COMPONENT ADJUSTMENT ......... 3-108 OPTIMAX AIR COMPRESSOR. .. . ... . .... 3·84 CHARGING CIRCUIT ••..•.....••.••..•. 4-40 ALTERNATOR....... .. ....... 4-46 DESCRIPnON &OPERATION ......... 4-46 REMOVAL & INSTALLATION. . . . 4-47 TESTING .. ... . •.... . 4-46 BATTERy. ... 4-43 CABLES. . .... ..... 4-45 CHARGERS. 4-45 CONSTRUCTION. . . . . . • . . .. 4_44 LOCATION. . . . . . . . . . . . . . . 4-45 MARINE BATIERIES 4-44 RAnNGS . ... . ......•.. 4-44 SAFETY PRECAunQNS . . . 4-45 DESCRIPTION AND OPERATION . 4-40 RECTIFIER. .. . . . . . .. 4-48 DESCRIPTION & OPERATION . . .. . ... 4-48 REMOVAl &INSTALLATION. 4-50 TESTING . . . .. 4-48 REGULATORlRECTIFIER .. . ... 4-50 REMOVAL &INSTALlATION. . . 4-51 TESTING. . . . . . . . . . . . . . . 4-50 SERVICE PRECAUTIONS . . . • 4-40 STATORIBATIERY CHARGECOIL 4-46 DESCRIPTION & OPERATION. . . 4-46 TESTING.. . . . . . . . . . • . .. . . . . . . . . 4-46 TROUBLESHOOTING .. ... ....... ... .. 4·41 ELECTRICAL SWITCH/SOLENOID SERVICE 4-64 IGNITION KEYSWITCH . . . • . 4·64 KILL SWiTCH.............. 4-64 NEUTRAL SAFETY SWITCH . . • . 4-65 START BUnON ........ . . . . . . . . . . . 4·65 IGN1110N SYSTEMS. . •• . •.. . .. ... . • . .• 4-8 CRANKSHAFT POSITION SENSOR . 4-30 DESCRIPTION &OPERATION . . 4·30 REMOVAL & INSTALLATION. 4-30 TESTING . . . . . . . . . . 4·30 ELECTRONIC IGNITiON SYSTEMS. . 4·8 COMPONENT TESTING. 4·12 DESCRIPTION & OPERATION . . .. .. 4-10 DIAGNOSTIC CHARTS..... .. .. .. ... 4-13 SYSTEM TYPES & COMPONENTS . • . . • 4-8 TROUBLESHOOTING. 4-11 FLYWHEEL .. ........... .. .. 4·21 REMOVAL & INSTALLATION. . . . 4-21 GENERAL INFORMATION. . . . . . . . . . . . . 4-8 IGNITION COILS 4·31 DESCRIPTION & OPERATION. 4-31 REMOVAL & INSTALlATION. 4·32 TESTING . . . . . . . . . . 4·31 IGNITION MODULE. . . . . . . . . . 4·34 REMOVAL & INSTALLATION. 4-37 TESTING . • . . • . . . . 4-34 STATOR/CHARGE COIL . . . . . . 4-25 DESCRIPnON & OPERATION . .... .... 4-25 REMOVAL & INSTALLATION. . . . . . . . .. 4·26 TESTING 4-25 TRIGGER COILS. . . . . . . . . . • . . 4-27 DESCRIPTION & OPERATION. 4-27 REMOVAL & INSTALLATION. . . 4-29 TESTING .... ... ...... ... 4·28 STARTER CIRCUIT. . . . . •• . •• . .. . 4-52 STARTER MOTOR. . . . . . . . . . 4-56 CLEANING & INSPECTION . . 4-62 DESCRIPTION . . . . . . . ... 4-56 REMOVAL& INSTALLATION. . . . ....• 4-56 OvERHAUL. . . . . . . .. . ........ .... 4·58 STARTER MOTOR C1RCU\TS . . 4-52 STARTER RELAY/SOLENOID. . . ... 4-54 DESCRIPTION &OPERATION. . .. 4-54 REMOVAL & INSTALLATION. . . 4·55 TESTING ... . . . . . . . . . • . . . . . . . . . . 4-54 UNDERSTANDINGAND mOUBLESHOOTING ELECmlCAL SYSTEMS. . •. . •• . •• . •• . •• 4-2 BASIC ELECTRICAL THEORY... 4-2 HOW DOES ELECTRICITY WORK . . . . 4·2 OHM'S LAW . . . . . . . . . . . . . . . . . . . . 4·2 ELECTRICAL COMPONENTS . . • . 4·2 GROUND. .. ....... 4-3 LOAD ..... .• . 4-4 POWER SOURCE. .. . 4·2 SWITCHES & RELAYS. . . . . .. . . .. 4-3 WIRING & HARNESSES. 4-4 ELECTRICAL TESTING. 4-6 PRECAUTIONS. . . . . . . . . . 4·8 TEST EQUIPMENT . .. . .• . . . 4-4 TROUBLESHOOTING. . . . . . . . . . . . . . . . 4-6 WIRE AND CONNECTOR REPAIR 4-7 SPECIFICATIONS ••.••... .••...•.. .... CHARGING SYSTEM TESTING . .. . . .. ... 4·43 KON~SYSTEMGruPONENTTEsnNG. . 4-39 STARTER BRUSH LENGTH. 4·63 WIRING DIAGRAMS. . •. . . • . . • . •• . •• .. 4-66 INDEX ••.•.•.••••..•..•.•••.•.•. • .• . 4-66 I-Cylinder Motors 2.513.3 Hp............... 4·67 415 Hp. . . . . . .. . . . . . . . . . . . . . . . . . . . . . 4-67 2-Cyllnder Molors 00, 9.9'1tY15 ~Manual Start wiBlack Stator.. 4-68 &-13, 9.9'10115 aoo 2C\I2O Je1i25 Hp Manual Start wIRed Stator .. . . . . . . . . . . 4-68 618, 9.9110/15 Hp MaralhonlSeaPro &20/25 Hp Work wlManuat Start & Red Stator. . . . . . .. 4·69 6/8, 9.9/10115 Hp Electric Start wffiller Handle Start Bullon & Black Stator. . . . . . . . . . 4-69 618, 9.9/10/15 & 20120 JeV25 Hp Electric Start wmtler Handle Start Button & Red Stator .. . 4·70 618, 9.9110/15 Hp Electric Start w/Remote Control & Black Stator. • . . . . . . . . . . . . . . .. HO 6IB, 9.9/10/15 &20120 Jet!25 Hp Electric Start wfRemote Control & Red Stator. . . . . . . . . . 4-71 30/40 Hp Manual Start wffiller Control 4-71 30 Hp Electric Start wffiller Control. . . . . . 4-72 30/40 Hp Electric Slart wlRemote Control. .. 4-72 30140 ~BectricStart wiRerrote Cctdra & m .. 4-73 3-Cylinder Molors 40/40 JeV50155!60 Hp Manual Start (MH) wffilierControl.................... 4-73 40/40 JeVS0I55!60 Hp (EO) Remote Electric . 4-74 40/40 JeV50/55 Hp (EHPTO) Remote Electric wlPn....... ....... . 4-74 40/40 JeU50155!OO Hp (EPTO) Remote Electric wlPn. . . . . . . . . . . . . . . . . . . . . 4-75 60 Hp (EHPTO) Remote Electric w/PTI . 4-75 65 Jet... ... ... ... ... ... .. 4-76 75 Hp Work {Manual StartlTilier Controij. . 4-76 75 Hp Electric StartlTilier Control w/PTI . 4-77 75190 Hp Electric StarVRemote Control. . . 4-77 75190 Hp Electric S1arVRemote Control w/PTI .........................•.... 4-78 Carbureted 4-Cylinder and V6 Molors 80 JeVll5!l25 Hp.... ........... 4-78 1501200 Hp (2.5L) Carbureted V6 . . .. 4-79 EFI V6 Motors 2001 1501175 Hp (2.5L) V6 EFI. .•. 4·80 2001 200 Hp (2.5L) V6 EFI . . . 4-82 2002·05 150·200 Hp (2.5L) V6 EFt . 4-84 2001 200-250 Hp (3.0L) V6 EFt 4-86 2002·05200-250 Hp (J.OL) V6 EFI 4·88 OptiMax 4-Cylinder and V6 Molors 75·115 Hp (1.5L) OptiMax ... . . . •..• . .•.. 4·90 135·175 Hp (2.5L) DptiMax. . . . . . . . . .. 4-92 200/225 Hp (3.0L) OptiMax 2001-2002 4-94 2003·052001225 Hp (3.0L) OptiMax Mechanical Shift. . . . . 4·96 2003-05200/225 Hp (3.0L) OptiMax Digital Thronle and Shift . . • . . . . 4·98 IRSlrumen\ Rigging -Carbureted &2001EFl Models Motor Instrument1.a1yrud Stop SWitt1 ~... 4·1 00 Instrument/Lanyard SlOp Switch Dual Outboard Rigging (Part A). . . . . . . . . •. • .. 4-100 InstrumenVLanyard Stop Switch Dual Outboard Rigging (Part B). ........ ... 4-101 Instrumenl Rigging -2002 and Later EFI Models tIctor Srnartaaft System Ta:11ometer & SpoojJmeIer hslallalion w/System lilk GaJges. . 4-102 Motor SystemMonitorfTachometer Installation w/System Unk Gauges . . . . .. ... .. . .. . 4-104 Dual Outboard Smartcraft installation . . . .. . 4-106 Instrument Rigging -OptiMax Models Smar1cratt (Non CAN) Installation .....•... 4-108 Smartcratt (CAN) Installation .. ........ ... 4-11 0 COOLING SYSTEM•.•. •••. , •.• , ••.•.•.••••.•.•••. •.•.••••.•••••.•.•.•.•.••• ~11 DESCRIPTION ANDOPERATION ....•.•....• '. . .•.....•....•.•.•...... 5·12 THERMOSTAT.... ..•.•.. .. ..•. ...••.......•.•...•.•.. ~15 EXPLODED VIEWS... . . . . . . . . . . . . . . .. .. . . . ........................ . ~18 REMOVAL &INSTALLATION.. .. .. . .. ... ... •................... . ~15 TROUBLESHOOTING... . • . . . • . . • . • . •••. . • . • . . •...••.....•.•.•.•.•.•...• 5·13 COOliNG SYSTEM... . • . • . . . . • . . . .. .. . . . . . ...................... . 5·14 THERMOSTAT. . . . . .. . . . . . . . . • . . . • . .• •.•••.••••.•••••....... _ &14 WATER PUMP............................ . .• •..•.•.••••...•.• ~19 CLEANING &INSPECTION. . • . •• .. . . . . . .. ...•....•••••........ &31 REMOVAL &iNSTALLATION. . . • . • . . • .• . ........•.•.•...•...••..... . ... 5·19 2.513.3 HP (NON-SHIFTlNG)MODELS .•..............••......•••....•. 5·19 2.513.3 HP (SHIFTING) & 4/5 HP MODELS . . .............•............. 5·21 618 &9.9/10115 HP MODELS ......•.• . .•.•.•.•.•.•. •.... 5·22 20120 JET125 HP MODELS. . . . . . • . . . • . . . . . . . . . . . . . ....•..... 5·24 30140 HP 2-CYL &40140 JET/50 HP 3·CYL MODELS.. ........... . ....... . 5·25 55/60 HP 3·CYL MODELS. . . . . . . • . . •...........•.•••.•........... ~26 65JET-125HP MODELS .......•...•.....•...............•..•...•...•.• >2, 135·200 HP (2.5L) V6 MODELS .............. ........................... . &29 200,250 HP (3.0l) V6 MODELS.. ....••......•.•.•.•.•.•.••••.•.......... ~30 COOLING SYSTEM flOW SCHEMATICS •••••....•••...•.•• , ••••••••••••••..•.. >41 OIL iNJECTION SYSTEM •••••..••.••••••••.•.•••••••••••••• .•.••••• , •••••••• 5·' GENERAl INFORMATiON . .. . • . .. .. .. . . . . . . . .. .. . .•.•.•.•.•.•..••......... 52 DESCRIPTION &OPERATION•.•.•..•.•.•.••• .•..•.•.•. •.•.•.•.......•..••. 5·2 ELECTRONIC MULTI·POINT (EMP)SYSTEMS. . .... .•.....•.•.•.•.•...... 5·2 ELECTRONIC SINGLE POINT (ESP) SYSTEM ...........•...•.•.•.•........... &2 MERCURY OIL INJECTION (SPVR. ESP & EMP) .....•.•.• , •.•.•.••• &2 OIL LINES...... ....... .. .. ..•.. .. ..•.•.... . .•.•...•.•.... 5·11 CAUTIONS....•.•.•....•.•.....................•...•.•.•.•.... 5·11 OIL PUMP.. .. .. .. . ................... . .•.•.•.•.•.•.•...........• ~9 CONTROL ROD ADJUSTMENT .. .. .. . .. .. •.......... .. ~11 REMOVAL &INSTALLATION. • . • . . . . . . . . •. . . .•.•.•.•..•.... &9 ELECTRONIC PUMPS. . • . . . . • •• . ••. . .. . . •• . .•.•.•.•.•.•••.... 5-10 ., MECHANICAl PUMPS. . • . • . .• . . . .•. ... . . •• . ..••.. .•.•.•••.•..•. OIL TANK .................................. ....•. •.•.•.•.•........ 5·6 CLEANING &INSPECTION. . . . • . . . •• . • . • .• . ......•.•.•.•.•.•..... ~ REMOVAL &INSTAlLATION . • . • . . • . . .......••..•.•.•••.•.•. •.•... .. 30·60 HP MODELS... .. ..•........... ..•.•.•.•.•......... 5~ 7~65 JETm AND 80 JETl1151125 HP MODELS ........•...•.•.•.......•.. &7 751901115 HP OPTIMAXMODELS ......... ............................ .. &7 135·275 HP MODELS. . . . . . . . . . . . . . . . . ....•.•...•.•.•... &B TROUBLESHOOTING AND SERVICE..................•....•...•.•.... .•. &3 BLEEDING THE SySTEM..................... ................... .... . &, OIL INJECTION SySTEM..... .. .. ..•.•.. .. .. .. . .....•.•.•........ 5·3 TESTING PUMPDISCHARGE RATE •.................••...•.•.•.....•..... 5·5 WARNING SYSTEM CIRCUIT. .............. . ..•.•••.•.•.•.•.•.......... 54 WARNING SYSTEMS•.•.••••.•.• ••••••••• •....••••••••.•.•.•••.•.•.•.•.•••. OIL AND TEMPERATURE WARNING SYSTEMS .. . . . . . . .. .. . ...•...•.•.•.•... 5·31 "" CHECKING .•••...••.•.•.••..........................•.•.•.•.•.• &31 OPTiMAX &CARUBURETEDtEFI V6 MOTOR WARNING SYSTEM TROUBLESHOOTING AWARNING SYSTEMACTIVATION •.•••.•.•..............• 5·32 OIL LEVEL SENSOR (SWITCH) •.•.... 540 DESCRIPTION &TESTING. . • . . . . . . . . . . . . . ....•.....•. 540 TEMPERATURESWITCH (WARNING SYSTEM) . ... ...... ........• &39 CHECKING SWITCH CONTINUITY . .. .. .... .. ............. .. 5·40 DESCRIPTION &OPERATION•......•.•.............•........ •...... ~39 TEMPERATURE SWITCH CHECK... .. . . ... .. .. .. ... .......... . 5·39 TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . .• .............••..•........ 5·33 SPECIFICATIONS ••.•.••.•.•.••••.•.•.•.•.•.••••• •.•.••• .•. •.•••. •.•.•.••. • >46 Coo...lNG SYSTEM SPECIFICATIONS. . • . . . . . • . ••. . •. •••...•.•.•........ . ..• >46 Oil TANK/PUMPCAPACITIES .••••.•.....••..• .. . ... ......•.•.••..•.•.•.•.•. 5·5 POWERHEAD BREAK·IN•••••••••••• .•• 6-69 BREAK·IN PROCEDURES •.•.•.•.••.•. 6-69 POWERHEAD MECHANICAL.. . . . .• • . . •. 6-2 GENERAL INFORMATION. . . . . . . . .. . .. 6-2 CLEANLINESS .. .. .. . .. .. .. • .. . 6-3 POWERHEAD COMPONENTS . • . • . . . 6-3 POWERHEAD OVERHAUL. . • . • . . . . •. 6-2 2.5/3.3 HP. .. . .. .. .. .. .. . .. .. 6·3 CLEANING & INSPECTION . . . 6-5 DISSASSEMBLY & ASSEMBLy .. .. . . . . 6-3 REMOVAL & INSTALLATION . • . • . • . . •. 6-3 415HP•.............. ...•.•.•.•••.. 6-5 CLEANING & INSPECTION. . • . • . •• . •. 6-6 DlSSASSEMBLY & ASSEMBLy........ 6-5 REUOVAL & INSTALLATION . . . • . . 6-5 618 & 9.9110115 HP . .... .. .. • .. .. . 6-8 CLEANING&INSPECTIQN ....•.•.•.. 6·12 DISSASSEMBLY &ASSEMBLy...... .. 6-8 REMOVAL & INSTALLATION . . . • . • . . .. 6-8 20120JET125 HP ...•. •.•..•.•.•.•..•. 6·12 CLEANING & INSPECTION ..•. ....... 6·16 DISSASSEMBLY&ASSEMBLY ..... ... 6-13 REUOVAL& INSTALLATION .. .... .. . . 6-12 30140 HP 2-CYlINOER ................ 6-17 ClEANING & INSPECTION •.•..••.... 6-22 DlSSASSEMBLY &ASSEMBLy ........ 6-18 REMOVAL & INSTALLATlON ...•...... 6·17 40140 JETISOI55I60 HP 3-CYUNOER •...• 6-22 CLEANING & INSPECTION ......•.... 6-27 DISSASSEMBLY &ASSEMBLy .•. •.... 6-23 REMOVAL & INSTALLATION .• .•... . . . 6-22 75165 JET190 HP &80 JET/II 51125 HP 6-27 CLEANING & INSPECTION • . . . .. .... . 6·35 DISSASSEMBLY & ASSEMBLY .. . .. . . . 6-28 REMOVAL & INSTALLATION . .. . ... . . . 6-27 751901115 HP OPTlMAX ............... 6-35 CLEANING & INSPECTION ..•.•.•..•• 6·42 DISSASSEMBLY & ASSEMBLy .••.•.•• 6-37 REMOVAL & INSTALLATION .•.•.•..•. 6-35 135-200 HP (2.51..) V6 .•.•..•. .....•.•• 6-42 CLEANING & INSPECTION. . 6-49 DISSASSEMBLY &ASSEMBLY .... 6-44 REMOVAL & INSTALLATION . . . . . . .... 6·42 200-250 HP (3.0l) V6 ... .. .. .. .. . 6-49 CLEANING & INSPECTION. .. . .• 6-57 DISSASSEMBLY&ASSEMBLY . 6-51 REMOVAL & INSTALLATION. • • . . 6-49 POWERHEAD RECONDITlONING ••••.•.• 6-57 BEARINGS ............ ....... ...... 6-66 GENERAL INFORMATION.. . ..... 6-66 iNSPECTION . . • . . 6·67 BUY OR REBUILD? . . . • . . .. 6-57 CONNECTING RODS .. ... . • . ..• . . . •. . 6·64 GENERAL INFORMATION. . . .• .. 6-64 INSPECTION.......... . 6-65 CRANKSHAFT .. .. .. .. . .. . . 6-65 GENERAL INFORMATION. • 6-65 INSPECTION.. .. .. .. .. .. .. .. . . 6~ CYliNDER BlOCK AND HEAD . . • . • 6-59 GENERAl INFORMATION . . . • 6-59 INSPECTION ..•.•.•.•.. .......... 6-60 CYLINDER BORES. • . . . . . . . . . •.• 6·60 GENERAL INFORMATION .... .....• . 6·60 INSPECTION. . . . . . .. 6·60 REFINISHING.. ......... ... 6·6\ DETERMINING CONDITION . . •• . •.•.• . . 6-57 OVERHAUL TIPS •.•.•.•.•.. .. ..•.•.• 6-58 CAUTIONS .. .............. .... ... 6-58 ClEANING ................ ....... 6-58 PISTONS .•.••.•.•.•.•.•.. . . . ••.. . . 6-62 GENERAL INFORMATION... ... . .. 6-62 INSPECTION.. ... ......... . ..... 6-62 PISTON PINS . .. .. .. ...... . .... .. .. . 6-63 GENERALINFORMATION. . . .. 6-63 INSPECTION •.•. •.• .•.. .. .. .. .... • 6-63 PISTON RINGS. . •.. . •... . ..• ... •. .. . 6·63 GENERAL INFORMATION ...... ...•.. 6-63 INSPECTION. . • . • . • . • . • . . . . . . . .. .. 6-64 PREPARATION...... ..... .. • .. 6-58 REED VALVES • .•.•.•.•.... ...... •.• 6-68 GENERAL INFORMATION •.•.... ..... 6-68 INSPECTION.. .. .. .. .. .. . . 6-6B SPECIACATION CHARTS •.•.• . ••••.•.• 6-70 ENGINE REBUILDING . 6-70 TORQUE. ....•...•.•.•.•.... .... ... 6·74 LOWER UNIT . • . •• •• . • . •• . • . •• •• . •• •• . • . •• •• •• •• •• .•. • . • . ••• . • . • . •• •• •• • 7·2 EXHAUST GASES . . .. . .. _....... . .. . . . . ...•....•. 7·3 GEARCASE· 2.513.3 HP MODELS (NON.sHIFTING) .. . .. .. .••.. 7·4 ASSEMBLy.............. ...................•.......•.. 7-7 CLEANING & INSPECTION. . . . . . . . . J.7 DiSASSEMBLy...... . . 7-4 REMOVAL & INSTALLATION.. .. .. ....... ... 7-4 SHIMMING. ........ .. .. ... .... 7·7 GEARCASE · 2.513.3 HP AND 41516 HP MODELS (SHIFTING) 7·8 ASSEMBLY 7·12 CLEANING & INSPECTION . . •. 7·12 DiSASSEMBLy............ . ....... , _.. 7·9 REMOVAL & INSTALLATION . 7·8 SHIMMING. ... .. ..... .. ... 7·16 GEARCASE -6·25 HPMQDELS . 7·16 ASSEMBLY. . .... . . . .. . . 7·20 CLEANING & INSPECTION . .... ..... .. 7·20 DiSASSEMBLy...... ..... .. ... .......... 7·18 REMOVAL & INSTALLATION 7·16 SHIMMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... , . 7·26 GEARCASE· 30140 HP (2-CYL) &40/50 HP (3-CYL) MODELS 7,26 ASSEMBLy... ...... ..... ........ 7·30 CLEANING & INSPECTION . 7·30 DiSASSEMBLy..... ........... ...... ... .. ... ...... 7-27 REMOVAL & INSTALLATION . . . . . 7-26 SHIMMING.. .. ... .. .. . .. .. .. ........ .. ........... .... ...... .... 7·34 GEARCASE· S5/6O (J..CYl) NCJN.BIGFOOT, 00 HP Bk3FOOT AND 75-125 HP M)DHS ... 7·34ASSEMBLy............... .......... . . ..................... 7·44 CLEANING & INSPECTION.. . .. .. .. .. ........ .. ........ 7·40 DiSASSEMBLy..... ...... .......... 7-36 REMOVAL & INSTALLATION 7-35 SHIMMING.. ..... ...... ... 7·48 GEARCASE -135-200 HP (2.5L) V6 MODELS. 7,51 ASSEMBLy........ ... 7-56 CLEANING & INSPECTION... ... .. .. .... .. 7·58 DISASSEMBLY . ..... ..... . .. .. .. •... ...• 7·52 REMOVAL & INSTALLATION.... . . ....•...... ,.... 7-51 SHIMMING .. ... .. ... .. 7.fJ2 GEARCASE . 200-250 HP (3.0L) V6 MODELS. 7·65 ASSEMBLy.......... .......... 7·73 CLEANING & INSPECTION. . . . . . . . . 7-70 DiSASSEMBLy........ . ..... ,... 7-66 REMOVAL & INSTALLATION . ..... ........ ...... ... 7·65 SHIMMING . . . . J.76 GEARCASE REPAIR &OVERHAUL TIPS . . 7·3 GENERAL INFORMATION.. ............... . ..... , . . 7-2 SHIFTING PRINCIPLES. . 7-2 COUNTER·ROTATING UNrT 7-3 STANDARD ROTATING UNrT. ..,.......... 7-2 TROUBLESHOOTING. . . . . . . . . • . . . . . . •. . . . 7-3 JET DRiVE .. ..................... .. ... •••.... ........ ........... .... 7·79 JET DRIVE ADJUSTMENTS J.86 GATE LINKAGE ADJUSTMENTS. . . . . . . . . . .. 7-86 GATE ADJUSTMENT.. ..... ........ 7-86 REMOTE CABLE ADJUSTMENT. . 7·86 TILLER SHIFT ROD ADJUSTMENT 7-86 TRIM ADJUSTMENT.... ..... .. 7·88.. JET DRIVE ASSEMBLy...... . . ....... , 7·79 ASSEMBLy... .. .. ...... 7-84 BEARING CARRIER OVERHAUL. .. ... . ,. .. 7·81 CLEANING & INSPECTION. . .. .. .... . .. ....... 7-82 DESCRIPTION & OPERATION..... ..... ..... 7·79 DRIVE ANDIOR IMPELLER REMOVAl. .... ... ,. 7-80 DRIVE AND/OR IMPBlER INSTAUATDN .......... . ......... 7-84 DRIVE UNIT DISASSEMBLY 7·81 GAS ASSIST TILT SySTEM••••.••••• ,... •••.•••••••• •••••• •••••••• •••••••.••• S.fi INTRODUCTION .........•...••••.••••••.•••••••..•..•••..•.•. ,........... 8-6 DESCRIPTION & OPERATION. ..................... .......................... 8-6 GASASSISTDAMPER................................................... 8-6 OVERHAUL (55·90 HP ONLy). . • . . . . • . . . . • . • . . . . . . . . . •. .. • . . .. . . 8-8 REMOVAL & INSTALLATION................ .................... 8·6 TESTING .... . ....•.............. •....... ,................. 8..s INTRODUCTION .•.. . . • . . . .. ........• ......••.......•...•...••... 8..s MECHANICAL TILT (UNASSISTED).................... ,........................ 8-2 DESCRIPTION &OPERATION .•................. ,... . • . • . •. • . . . • . ••. . . . . . . . .. 8-2 INTRODUCTION ................................................ .......... 8-2 SERVK:tNG . . . . . . . •. •. . . . •• . • . . . . • . •• . • .• ..•........•.....•.•...•.•.•... 8-2 POWERTILTITRIM -SINGLE RAMINTEGRAl. .......... " ....................... 8-10 DESCRIPTION &OPERATION................................................ 8-10 INTRODUCTION .......................................................... 8-10 PIT ASSEMBLY (SINGLE RAM ASSEMBLy) .•..•.•. •• •.•.•.••...... , •• •.•.. ..... 8-15 BLEEDING.. ..................... . .•.•..........•.•.•........ ... 8-15 OVERHAUL.. ....•.. ..•.. ..... ..•.•.. ... . ... , •...•.•.•••.•.•..... 8·16 REMOVAL & INSTALLATION............ •.................. .... ....... 8·15 TROUBLESHOOTING ............ ... ...... . ... ... ... . 8·11 COMPREHENSIVE TESTING..... ..... . . ............................ 8·11 GErnNG STARTED................. ....................... 8-11 SYMPTOM DIAGNOSIS CHARTS. . . . . . . • . •• .. . . . • . • . • . . . . . . . . . . ... 8-11 MOTOR WILL NOT HOLD TILTED POSITIONDURING REVERSE, ANDIOR mAR-SOUT DURING HIGH SPEED DECELERATION).•..........•.•.•.•.•.•••. 8-12 TRIM SYSTEM LEAKS DOWN WITH MANUAL RELEASE VALVE CLOSED . . 8·12 WIRING DIAGRAM AND CIRCUIT TESTING. ....... .. .. .•.. .. 8-11 30·50 HP MOTORS... ..•.. ..•.•.. ..•.. .. .. ............. .. .. .. .. .. 8-13 55160 HP MOTORS .. .. .. .. ...... .. .. ..... .. .. .. .. ...... 8·13 65JET-125HPMOTORS....... . ..................... 8-14 TROUBLE CHART .. ..•.. ..•.•..•.•.. ... . .....•......•...•.•.•.•..• 8,14 POWERTILTITRIM -THREERAM ItfTtGRAL ••.•.•.••••••••••••.•...•••.•.•.•.•• 8-20 DESCRIPTION AND OPERATION •.•.••.•......•.•...•.•.••.•....••.. .•.•.•.•• 8·20 INTROOUCTION ........ ...... ................ ...... . ............ . ... 8-20 PIT ASSEMBLY (3 RAM ASSEMBlY) ................................ .......... 8-25 HYDRAULIC SYSTEM BLEEDING •.••••.•.••••••.•.•.•. •...••.......•...•. . . 8-27 REMOVAL & INSTALLATION............... ..... , ........................... 8-25 TILT ROO ............................................................... 8·29 REMOVAL & INSTALLATION............................................... 8-29 TRIM MOTOR AND PUMP. ........... .. . . .. ... .. ....... ....... ..... 8·31 REMOVAL &INSTALLATION•..•.•.•..•.•..............•.......•..•.•.•.••. 8-31 TESTING THE MOTOR.. .. . . . . . • . . . . • . .. .. .......... ........... .. 8·31 TRIM ROD AND CAP. . •• . • . . . .. . . . . . . • .. .. •.. . . . . . . . . •. . . . . . .. 8-27 REMOVAL & INSTALLATION. ..... .•.••..... . ......................... 8-27 TRIM SENDERANDGAUGE. . . •• . • . •• •••. . • . .. ••• .•.•.•••••.•.••........ .. 8-32 ADJUSTING THE SENDER .••...•........•..•.•.......•..••.••.•.•.•.•..... 8-33 TESTING............................................................. 8-32 WIRING DIAGRAMS. . . .. . . . . . . . . • . .. . . . .. .. .••. •• . • . •. • . • . • . . . . . .. . . . 8·33 TRIM SENDER AND GAUGE WIRING. . . . . . . •. . . . . . . ••• . • . • . ••• . •• . • • . 8-33 TROUBLESHOOTING.. .....•....•.•....• • •...•.•.• ' • . • . • . • . . . . . . . . . 8·21 COMPREHENSIVE TESTING. . . . . . . . . . . . . . • . . . . . . . . •. • . • . • . • . • . . . • . . . 8-21 GEntNG STARTED. . . . • . . . . • . • . . ....•.....•.•...•.•.••..•......•. 8-21 SYMPTOM DIAGNOSIS .. .. . . . .. . . . . ... .... ......... . ....... . . .......... 8·21 TYPE I (SHOWA SYSTEMS) .... . . • . . . . . .. . . . . . • . • . . 8-22 TYPE II (OILDYNE SYSTEMS). . • . . • •• . • . . . . • . • . • . ••. • • . . . ••. . . . . . .. .. 8-22 WIRING DIAGRAM &CIRCUIT TESTING. . .. .. .. • . . . .. . . • . •• •• •• . • •• . • .• .. 8-23 TROUBLESHOOTING BY SYMPTOM. • . •• . .. .....•.........•.•......... 8-23 V6 MOTORS (BOTH TYPE IAND 11 SYSTEMS). .. ......................... 8·23 TROUBlESHOOTING THE DOWN CIRCUIT -V6 PIT SYSTEMS . • . •• •• . • •• . •. ... 8-24 TROUBlESHOOTING THE UP CIRCUIT -V6 PIT SYSTEMS. . • . • . . . . . . . . . .. .. .. 8-24 TROUBlESHOOTING THE DOWNIUP CIRCUITS -V6 PIT SYSTEMS. • . • . •• . • . • 8-25 REMOTE CONTROLS .•• ••••••••••••••.•.••••••••0 •••••• 0 ••••••• 0 0.. •• •• • 9-2 REMOTE (SHIFT AND THROmE) CABLES .• . . ••• . . • . • . • •• . • . • . • . .. 9·5 INSTALLATION &ADJUSTMENT. . .. .. . . . . . ...•0" 9·5 40·125 HP (3· AND 4·CYLj MODELS... ................ 9·5 135·250 HP (V6) MODELS...... .. .. ........ 9·6 SIDE MOUNT REMOTE CONTROL BOX (MERCURY) . . . . . . . . . . . . . . . • . •. 9·2 ASSEMBLY. ..•.•.•..•.. .. ..•.•..•. 9-4 CLEANING & INSPECTING.. • . . .. .. .. .. . .. .. . .. . g·4 DESCRIPTION &OPERATION. . .... o .......'" ... 9·2 DISASSEMBLY. ...... ..... ......•.•.•.• 9·3 REMOVAL & INSTALLATION .. . . . . . . • . .. . .. .. .. .. .. .. .. .. 9·2 TROUBLESHOOTING. . .. .. . .. • • . . . . .. ... .. .. .. •. .. .. .. .. .. 9·2 TILLER HANDLE••• , •.• , ••••.••••.... , •• o0 •• • •••••• 0 ••••••• 0 0 ........ . . 9-7 0 • CONTROL CABLES. ... ......... ..... . .............................. 9·12 REMOVAL 8 INSTALLATION ........ .. .. 0 ....... . ....... ... ......... 9,12 2.513.3 HP MODELS..... . . .... ..... 0 ..... ........... .. 9-12 415 HP MODELS........ . . .......................... g·12 &25 HP MODELS.. ..... ..... • ...•.•.•••. •.•.•.•.•.•...•..• g·12 30/40 HP & 4OJ5O HP (2· AND 3-CYL) MOOELS . . . . ................. 9-13 55 HP & LARGER MODELS ............... ... . .•.•.•..• 9·13 DESCRIPTKJN& Of'ERATION .................. .... ............ 9-7 TILLER HANDLE. • . • . • . . • . . . .. . • .. . • . • . • . . . . .. . . . . . . . 9·7 REMOVAL & INSTALLATION............ ............................ 9-7 2.~.3 HP MODELS ..... .. ... ............. . .. ................... ... 9-7 415 HP MODELS. . .. . . . . . .. . . . . . . . . . . . . .. . . .. . . •. • . • . • . • . • . • . • . . . .. 9-7 &25 HP MOOELS. . • . • . • . •• . • . • . . . . . . . . •. . . .. . .. •...•.•..... 9-9 30140 HP & 4OJ5O HP (2· AND 3-CY1...) MOOELS..... . ..................... g·10 55 HP & LARGER MODELS .. ... ... .......... . . .. . ... .. .. .......... g,'1 TROUBLESHOOTING. . . . • . .. . . . . . . • . • . • . • . • . •• • . .. 9-7 WIRING DIAGRAMS .•. ,., •.• .••...••.•..... ....•.•.•.•.•.•.•.•.•.•.•.•.•..• 9·14 6-25 HP MaTGAS COMMANDER 2000 KEYICHOKESWITCH. . . . . . . • . . . . . • . • . • . . . . . . .• . . ........ 9-14 WD &CONTINUITY TEST CHART· COMMANDER 2000 KEY SWiTCHES .• ..••..•.... 9-15 COMMANDER REMOTE CONTROl· MAN. STARTW!O PIT .• .•.•.•.•.•.•.•....... 9·15 COMMANDER REMOTE CONTROL· ELEC. START W!O PIT .....•............... 9·16 COMMANDER 2000 REMOTE CONTROL· ELEC. START... . . . ..... .....• 9·16 COMMANDER 3000 PANEL MOUNT REMOTE CONTROl .......... .. ........•.•.. 9·17 30·125 HP MOTORS...... ..... .............. •...•.•.•.•.• •.•.......... . 9·17 COMMANDER 2000 KEYICHOKE SWiTCH ....... . ............•.•. •.•.•.•.•.•.. 9·14 WD 8CONTINUITY TEST CHART • COMMANDER 2000 KEY SWiTCHES •.•...•.•.•.. 9-15 COMMANDER 2000 SIDE MOUNT· ELEC. STARTWIPIT & WARN HORN ....... •.... 9-17 COMMANDER 2000 SIDE MOUNT· ELEC. START WIO PIT & WfWARN HORN ... ..... 9-18 MERCURY PANEL MOUNT REMOTECONTROL ... ............................ 9-18 MERCURY REMOTE KEY SWITCH & WARNING HORN ....•.•.•.•••.•.•.•.•.•...• 9-19 MERCURY SIDE MOUNT REMOTE CONTROl .....................•.•.•.•.•.... 9-19 INSTRUMENTISTOP SWITCH WIRING· MERCMIO·RANGE MOTORS ...... ..•.•...• 9·20 INSTRUMENTISTOPSWITCH WIRING · MERC MID-RANGE MOTORS ON A DUAl·OUTBOARD INSTAlLATION .........•....•...•.•••.•.•.•.•.•.•.•.....• 9·20 V6 MOTORS .....•.................................•.•.•.•.•.•.•.•.•.•.... 9-21 MERCURY SIDE MOUNT REMOTE CONTROl ......................... ..•.•.•.• 9-21 COMMANDER 2000 KEYICHOKESWITCH .•..•...........................•.... 9-14 WO & CONTINUITY TESTCHART· COMMANDER 2000 KEY SWITCHES •.. ..... ....• 9-15 MECHANICAL PANELCONTROl (MPC) 400J................................... 9-22 HANO REWIND STARTER. . •• •• •. . •• .. . . . . . .. . . . . . .•• •••.••••••••.•.•.• 10.2 DESCRIPTION AND OPERATION ... .. . . ........ . . .... .. . ................ 10-2 TROUBLESHOOTING THE HAND REWIND STARTER . •...•.• 10-2 2.513.3HP MODELS..... ............. . .... . ... ....... 10-2 ASSEMBLY 8 INSTAlLATION.......... .... ..... ...... 10-3 CLEANING 8 INSPECTION ..... .. ......... ... ...... .. ....... 10-2 REMOVAL 8 DISASSEMBLy........... ,. .... , ....•.•.•...•.•.• 10-2 415 HP MODELS . . . . . . . . •. . . .. . ...... ,.... ••...... ,•.......•.•.•.•.• 1().4 ASSEMBLY8INSTALLATlON................. .. ......................... 10.6 CLEANING 8 INSPECTION . • . • . .. .. •.................. ................ HI·6 REMOVAl 8 DISASSEMBLY .............. .. ....... llJ.4 6-25 HP MODELS............... .. .. .................. 10.8 ASSEMBLy................... • .•.....•.•. ..•.•.• 10-11 CLEANING 8 INSPECTION ....... .. .... .. ....... 10·10 DiSASSEMBLy................ ...•.•.......•...•...• 10-10 REMOVAL 8. ROPE REPLACEMENT ....................... 10·8 ROPE REPLACEMENT 8. INSTALLATION. ..•.. ••...•.•. •.•.•.... 10-11 30 HP AND LARGER MODELS . .. .. .... •.............. 10·11 ASSEMBLY 8. INSTALLATION . ............ ..... .. .. .. ............. 10·14 CLEANING 8. INSPECTION .. .. .... ... . ...... 10-14 REMOVAL 8. DISASSEMBLY ..... .... .......... ..................... 10·11