CONTENTS 1 GENERAL INFORMATION, SAFETY & TOOLS …

1 1 GENERAL INFORMATION, SAFETY & TOOLSHOW TO USE THIS MANUAL1-2 BOATING SAFETY1-4 BOATING EQUIPMENT (NOT REQUIREDBUT RECOMMENDED)1-10 SAFETY IN SERVICE1-12 TROUBLESHOOTING1-13 SHOP EQUIPMENT1-17 TOOLS1-19 FASTENERS, MEASUREMENT, AND CONVERSIONS1-27 SPECIFICATIONS1-282 MAINTENANCE &TUNE-UPGENERAL information (WHAT EVERYONE SHOULD KNOW ABOUT MAINTENANCE)2-2 LUBRICATION2-4 ENGINE MAINTENANCE2-10 BOAT MAINTENANCE2-29 TUNE-UP2-32 STORAGE (WHAT TO DO BEFORE AND AFTER)2-76 CLEARING A SUBMERGED MOTOR2-79 SPECIFICATIONS2-813 FUEL SYSTEMFUEL & COMBUSTION BASICS3-2 FUEL TANK & LINES3-6 CARBURETED FUEL SYSTEM3-12 ELECTRONIC FUEL INJECTION (EFI)3-45 OPTIMAX DIRECT FUEL INJECTION (DFI)3-73 FUEL/OIL ROUTING DIAGRAMS (EFI)3-115 AIR/FUEL ROUTING DIAGRAMS3-117 SPECIFICATIONS3-1214 IGNITION & ELECTRICALSYSTEMSUNDERSTANDING & TROUBLESHOOTINGELECTRICAL SYSTEMS4-2 IGNITION SYSTEMS4-8 CHARGING CIRCUIT4-39 DESCRIPTION & OPERATIONSPECIFICATIONSSTARTER CIRCUIT4-51 ELECTRICAL SWITCH/SOLENOID SERVICE4-61 WIRING DIAGRAMS4-645 COOLING & LUBRICATIONOIL INJECTION SYSTEM5-2 COOLING SYSTEM5-11 WARNING SYSTEMS5-31 COOLING SYSTEM FLOW SCHEMATICS5-41 SPECIFICATIONS5-44 CONTENTSCONTENTSPOWERHEAD MECHANICAL6-2 POWERHEAD RECONDITIONING6-60 POWERHEAD BREAK-IN6-71 SPECIFICATION CHARTS6-73 POWERHEADMASTER INDEX 10-15 MASTER INDEX6 LOWER UNIT7-2 TROUBLESHOOTING7-3 JET DRIVE7-88 LOWER UNIT7 MECHANICAL TILT (UNASSISTED)

2 8-2 GAS ASSIST TILT SYSTEM8-6 POWER TILT/TRIM - MID-RANGEMOTOR, SINGLE RAM INTEGRAL8-14 POWER TILT/TRIM - MID-RANGEMOTOR, SINGLE RAM8-19 POWER TILT/TRIM SYSTEM -3 RAM INTEGRAL8-24 POWER TILT/TRIM SYSTEM -3 RAM INTEGRAL8-29 TRIM & TILT8 REMOTE CONTROLS - MECHANICAL UNITS9-2 REMOTE CONTROLS - DIGITAL THROTTLE & SHIFT (DTS) UNITS9-11 TILLER HANDLE9-16 REMOTE CONTROL WIRING9-22 REMOTE CONTROL9 HAND REWIND STARTER10-2 HAND REWIND STARTER10 ADDITIONAL REMOTE UNITS .. 9-6 EXPLODED VIEWS .. 9-6 AIR/FUEL ROUTING DIAGRAMS (OPTIMAX) .. 3-117 AIR COMPRESSOR.. 3-78 DESCRIPTION & OPERATION .. 3-78 OVERHAUL .. 3-84 REMOVAL & INSTALLATION .. 3-83 TESTING .. 3-78 AIR FILTER .. 2-27 REMOVAL & INSTALLATION .. 2-27 AIR PRESSURE REGULATOR .. 3-87 DESCRIPTION & OPERATION .. 3-87 REMOVAL & INSTALLATION .. 3-88 TESTING .. 3-88 AIR TEMPERATURE SENSOR (ATS) .. 3-58 DESCRIPTION & OPERATION.

3 3-58 REMOVAL & INSTALLATION .. 3-58 TESTING .. 3-58 ALTERNATOR (EXTERNAL) .. 4-45 DESCRIPTION & OPERATION .. 4-45 REMOVAL & INSTALLATION .. 4-46 TESTING .. 4-45 ANODES (ZINCS) .. 2-24 INSPECTION .. 2-24 SERVICING .. 2-25 BASIC ELECTRICAL THEORY .. 4-2 HOW DOES ELECTRICITY WORK: THE WATER ANALOGY .. 4-2 OHM S LAW .. 4-2 BATTERIESBATTERY CHARGERS .. 4-44 CONSTRUCTION .. 4-43 LOCATION .. 4-43 MAINTENANCE .. 2-29 CLEANING .. 2-30 ELECTROLYTE LEVEL .. 2-29 MARINE BATTERIES.. 4-42 RATINGS .. 4-43 REPLACING CABLES .. 4-44 SAFETY PRECAUTIONS .. 4-43 STORAGE .. 2-31 TESTING .. 2-30 BEARINGS .. 6-70 INSPECTION .. 6-70 BEFORE/AFTER EACH USE.. 2-2 VISUALLY INSPECTING THE BOAT & MOTOR.. 2-3 BOAT MAINTENANCE .. 2-29 BATTERIES .. 2-29 FIBERGLASS HULL .. 2-31 INTERIOR .. 2-32 BOATING EQUIPMENT (NOT REQUIRED BUT RECOMMENDED) .. 1-10 ANCHORS .. 1-10 BAILING DEVICES.

4 1-10 COMPASS .. 1-10 FIRST AID KIT .. 1-10 OAR/PADDLE .. 1-10 TOOLS AND SPARE PARTS .. 1-12 VHF-FM RADIO .. 1-10 BOATING SAFETY .. 1-4 COURTESY MARINE EXAMINATIONS .. 1-10 REGULATIONS FOR YOUR BOAT .. 1-4 REQUIRED SAFETY EQUIPMENT .. 1-5 BUY OR REBUILD? .. 6-60 CARBURETED FUEL SYSTEM .. 3-12 DESCRIPTION & OPERATION .. 3-12 ENRICHENER SYSTEMS .. 3-41 FUEL PUMP .. 3-37 TROUBLESHOOTING THE FUEL SYSTEM .. HP MODELS .. 3-18 CLEANING & INSPECTION .. 3-20 OVERHAUL .. 3-19 REMOVAL & INSTALLATION .. 3-184/5 HP MODELS .. 3-21 CLEANING & INSPECTION .. 3-24 OVERHAUL .. 3-23 REMOVAL & INSTALLATION .. 3-216/8, & 20/20 JET/25 HP MODELS .. 3-25 CLEANING & INSPECTION .. 3-28 OVERHAUL .. 3-26 REMOVAL & INSTALLATION .. 3-2530/40 HP 2-CYLINDER MODELS .. 3-28 CLEANING & INSPECTION .. 3-31 OVERHAUL .. 3-29 REMOVAL & INSTALLATION .. 3-2840-125 HP 3 & 4-CYLINDER MODELS.

5 3-32 OVERHAUL .. 3-33 REMOVAL & INSTALLATION .. 3-32150/200 HP ( ) V6 MODELS .. 3-34 CLEANING & INSPECTION .. 3-37 OVERHAUL .. 3-35 REMOVAL & INSTALLATION .. 3-34 CHARGING CIRCUIT .. 4-39 ALTERNATOR (EXTERNAL) .. 4-45 BATTERY .. 4-42 DESCRIPTION & OPERATION .. 4-39 RECTIFIER .. 4-47 REGULATOR/RECTIFIER .. 4-49 SERVICE PRECAUTIONS.. 4-39 STATOR/BATTERY CHARGE COIL (UNDER FLYWHEEL) .. 4-44 TROUBLESHOOTING .. 4-40 CLEARING A SUBMERGED MOTOR.. 2-79 COMBUSTION .. 3-6 ABNORMAL COMBUSTION .. 3-6 COMBUSTION RELATED PISTON FAILURES.. 3-6 FACTORS AFFECTING COMBUSTION .. 3-6 COMMANDER SIDE MOUNT REMOTE CONTROL BOX (MERCURY).. 9-2 ASSEMBLY .. 9-5 CLEANING & INSPECTING .. 9-5 DESCRIPTION & OPERATION .. 9-2 DISASSEMBLY .. 9-3 REMOVAL & INSTALLATION.. 9-2 TROUBLESHOOTING .. 9-2 COMPRESSION TESTING .. 2-33 LEAK TESTING .. 2-35 LOW COMPRESSION .. 2-34 TUNE-UP COMPRESSION CHECK.

6 2-33 CONNECTING RODS .. 6-68 INSPECTION .. 6-68 CONTROL CABLES .. 9-20 REMOVAL & INSTALLATION .. HP MODELS.. 9-204/5 HP MODELS.. 9-206-25 HP MODELS.. 9-2030/40 HP & 40/50 HP (2- AND 3-CYL) MODELS.. 9-2155 HP & LARGER MODELS .. 9-21 COOLING SYSTEMDESCRIPTION & OPERATION .. 5-12 FLUSHING THE COOLING SYSTEM .. 2-10 FLUSHING JET DRIVES .. 2-12 THERMOSTAT .. 5-15 TROUBLESHOOTING .. 5-12 WATER PUMP .. 5-19 COOLING SYSTEM FLOW SCHEMATICS.. 5-41 CRANKSHAFT .. 6-69 INSPECTION .. 6-69 CRANKSHAFT POSITION SENSOR (CPS)DESCRIPTION & OPERATION .. 4-27 EFI .. 3-60 OPTIMAX .. 3-91 TESTING .. 4-27 CYLINDER BLOCK & HEAD .. 6-62 GENERAL information .. 6-62 INSPECTION .. 6-63 MASTER INDEX 10-15 CYLINDER BORES .. 6-63 INSPECTION .. 6-64 REFINISHING .. 6-64 DESCRIPTION & OPERATIONAIR COMPRESSOR .. 3-78 AIR PRESSURE REGULATOR .. 3-87 AIR TEMPERATURE SENSOR (ATS).

7 3-58 ALTERNATOR (EXTERNAL) .. 4-45 CARBURETED FUEL SYSTEM.. 3-12 CDI & MODULAR CDI SYSTEMS .. 4-10 CHARGING CIRCUIT .. 4-39 COMMANDER SIDE MOUNT REMOTE CONTROL BOX .. 9-2 COOLING SYSTEM .. 5-11 CRANKSHAFT POSITION SENSOR (CPS) .. 4-27 DETONATION (KNOCK) SENSOR & MODULE .. 3-61 DIRECT INJECTOR .. 3-96 ELECTRIC FUEL PUMP - EFI .. 3-67 ELECTRIC FUEL PUMP(S) - OPTIMAX .. 3-104 ELECTRONIC/ENGINE CONTROL MODULE (ECM) .. 3-62 ELECTRONIC FUEL INJECTION (EFI) .. 3-45 ENGINE TEMPERATURE SENSORS (ETS) .. 3-55 ENRICHENER SYSTEMS .. 3-41 FUEL INJECTOR - OPTIMAX .. 3-97 FUEL INJECTORS, FUEL RAIL, REED ASSEMBLY &AIR INTAKE PLENUM EFI .. 3-47 FUEL PRESSURE REGULATOR - EFI .. 3-72 FUEL PRESSURE REGULATOR - OPTIMAX.. 3-98 FUEL (AND AIR) RAIL .. 3-106 GAS ASSIST TILT SYSTEM .. 8-6 HAND REWIND STARTER .. 10-2 IGNITION COILS .. 4-28 IGNITION MODULE (CD UNIT/CDM).

8 4-331 INJECTION SYSTEM .. 5-4 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR - EFI .. 3-58 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR - OPTIMAX.. 3-92 MECHANICAL FUEL PUMP - EFI .. 3-63 MECHANICAL TILT (UNASSISTED) .. 8-2 OIL LEVEL SENSOR (SWITCH) .. 5-40 OPTIMAX DIRECT FUEL INJECTION (DFI) .. 3-73 PCM & DIGITAL INDUCTIVE SYSTEMS.. 4-11 PTT - SMALL MOTOR, SINGLE RAM INTEGRAL .. 8-10 PTT - MID-RANGE MOTOR, SINGLE RAM INTEGRAL.. 8-14 PTT - 3 RAM INTEGRAL .. 8-24 RECTIFIER .. 4-47 REMOTE CONTROLS - DTS UNITS.. 9-11 SHIFT INTERRUPT SWITCH .. 3-94 STARTER MOTOR .. 4-55 STARTER MOTOR CIRCUITS .. 4-51 STARTER RELAY/SOLENOID.. 4-53 STATOR/CHARGE COIL .. 4-22 STATOR/BATTERY CHARGE COIL (UNDER FLYWHEEL) .. 4-44 TEMPERATURE SENSORS (ATS, CTS AND ETS) .. 3-89 TEMPERATURE SWITCH (WARNING SYSTEM) .. 5-38 THROTTLE POSITION SENSOR (TPS) - EFI .. 3-60 THROTTLE POSITION SENSOR (TPS) - OPTIMAX.

9 3-91 TILLER HANDLE .. 9-16 TRACKER VALVE (V6 ONLY) .. 3-107 TRIGGER COILS .. 4-25 VAPOR SEPARATOR - OPTIMAX.. 3-108 VAPOR SEPARATOR TANK (VST) ASSEMBLY - EFI .. 3-68 WATER SENSOR .. 3-62 DETERMINING POWERHEAD CONDITION.. 6-60 DETONATION (KNOCK) SENSOR & MODULE .. 3-61 DESCRIPTION & OPERATION .. 3-61 TESTING .. 3-61 DIGITAL REMOTE UNITS .. 9-14 EXPLODED VIEWS .. 9-14 DIRECT INJECTOR .. 3-96 DESCRIPTION & OPERATION .. 3-96 REMOVAL & INSTALLATION .. 3-96 TESTING .. 3-96 DRIVE BELT .. 2-25 INSPECTION .. 2-26 REMOVAL & INSTALLATION .. 2-26 ELECTRIC FUEL PUMPEFI .. 3-67 OPTIMAX .. 3-104 ELECTRICAL COMPONENTS.. 4-2 GROUND .. 4-3 LOAD .. 4-3 POWER SOURCE .. 4-2 PROTECTIVE DEVICES .. 4-3 SWITCHES & RELAYS .. 4-3 WIRING & HARNESSES .. 4-4 ELECTRICAL SWITCH/SOLENOID SERVICE .. 4-61 IGNITION KEY SWITCH .. 4-61 KILL SWITCH .. 4-62 NEUTRAL SAFETY SWITCH.

10 4-63 START BUTTON .. 4-63 ELECTRICAL TESTING .. 4-6 OPEN CIRCUITS .. 4-6 RESISTANCE.. 4-6 SHORT CIRCUITS .. 4-6 VOLTAGE .. 4-6 VOLTAGE DROP .. 4-6 ELECTRONIC ENGINE/PROPULSION CONTROL MODULE (ECM)EFI .. 3-62 OPTIMAX .. 3-95 ELECTRONIC FUEL INJECTION (EFI) .. 3-45 AIR TEMPERATURE SENSOR (ATS) .. 3-58 CRANKSHAFT POSITION SENSOR (CPS) .. 3-60 DESCRIPTION & OPERATION .. 3-45 DETONATION (KNOCK) SENSOR & MODULE .. 3-61 ELECTRIC FUEL PUMP .. 3-67 ELECTRICAL SYSTEM CHECKS .. 2-40 BATTERY .. 2-40 INTERNAL WIRING HARNESS.. 2-40 STARTER MOTOR .. 2-40 ELECTRONIC/ENGINE CONTROL MODULE (ECM) - EFI .. 3-62 ELECTRONIC/PROPULSION CONTROL MODULE (ECM/PCM) -OPTIMAX .. 3-95 ENGINE TEMPERATURE SENSORS (ETS) .. 3-55 FUEL INJECTORS, FUEL RAIL, REED ASSEMBLY & AIR INTAKEPLENUM .. 3-47 FUEL PRESSURE REGULATOR .. 3-72 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR.