TABLE OF CONTENTS 3 MAINTENANCE

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Erick Lawrence
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1 TABLE OF CONTENTS 1 SAFETY " FUEL 1-1 CLEANING, WAXING, &: POLISHING 1-1 CONTROLLING CORROSION 1-1 PROPELLERS 1-2 FUEL SYSTEM 1-7 LOADING 1-9 HORSEPOWER 1-10 FLOTATION 1-10 EMERGENCYEQUWMENT 1-12 COMPASS 1-14 STEERING 1-16 ANCHORS 1-16 MISCELLANEOUS EQUIPMENT 1-17 BOATING ACCIDENT REPORTS 1-17 NAVIGATION TUNING 2-1 TUNE-UP SEQUENCE 2-2 COMPRESSION CHECK 2-3 SPARK PLUG INSPECTION 2-3 IGNITION SYSTEM 2-4 TIMING AND SYNCHRONIZING 2-5 CARBURETOR ADJUSTMENT 2-7 FUEL PUMPS 2-9 CRANKING MOTOR AND SOLENOID 2-10 INTERNAL WIRING HARNESS 2-11 WATER PUMP CHECK 2-12 PROPELLER 2-13 LOWER UNIT 2-15 BOAT TESTING MAINTENANCE 3-1 OUTBOARD SERIAL NUMBERS 3-2 LUBRICATION - COMPLETE UNIT 3-2 PRE-SEASON PREPARA TION 3-6 FIBERGLASS HULLS 3-10 BELOW WATERLINE SERVICE 3-10 SUBMERGED ENGINE SERVICE 3-11 PROPELLER SERVICE 3-13 POWER TRIM/TILT 3-15 INSIDE THE BOAT 3-16 LOWER UNIT 3-16 WINTER STORAGE GENERAL CARBURETION INFORMA TION 4-1 TROUBLESHOOTING 4-5 "Sour" Fuel 4-6 Leaded Gasoline &: Gasohol 4-6 Removing Fuel From System 4-7 Fuel Pump Test 4-9 Fuel Line Test 4-11 Rough Engine Idle 4-12 Excessive Fuel Consumption 4-12 Engine Surge 4-13 CARB URE TOR IDE NTIFICA TION 4-13 CARBURETOR "A" - SIDE BOWL AND BACK DRAG 4-14 &: 4-14 Cleaning &: Inspecting 4-16 &: Installation 4-20 Adjustments 4-24 CARBURETOR lib" V6 POWERHEADS DUAL FLOAT CENTER BOWL 4-25 &: 4-25 Cleaning &: Inspecting 4-27 &: Installation 4-29 CARBURETOR "C" - CENTER SQUARE BOWL 4-33 &: 4-33 Cleaning &: Inspecting 4-37 &: Installation 4-37 FUEL PUMP 4-42 Theory of Operation 4-42 Pump Pressure Check 4-43 Pump 4-44 Cleaning &: Inspecting ELECTRONIC FUEL INJECTION (EFI) 4-47 General Informa tion 4-47 System 4-47 EFI 4-55 EFI MAINTENANCE 4-62 Removing Fuel from System 4-63

2 " FUEL (Continued) SERVICING EFI Intake Manifold &. Injectors Cleaning &. Inspecting &. Installation Fuel Filter Service Fuel Pressure Regulator &. Vapor Separator Service Throttle Sensor Service OIL INJECTION SYSTEM "Auto Blend" System Storing the System Prep. for Use Advanced Oil Injection Operation Filling System Purging Air Oil Pump Adjustment ELECTRONIC "BLACK BOX" MODULES 5-38 Operation TIMING AND SYNCHRONIZING &. PREPARATION 6-1 IGNITION TIMING AND CARB SYNCHRONIZATION 6-3 ELECTRONIC IDLE STABILIZER AND SPARK ADVANCE MODULES 6-6 MODEL MODEL MODEL MODEL MODEL 950SS MODEL 1100SS MODEL 950SS &. 1100SS MODEL 1000SS MODEL 1250SS IGNITION SPARK PLUG EVALUATION POLARITY CHECK WIRING HARNESS TYPE I SYSTEM - DISTRIBUTOR WITH POINTS Troubleshoo ting Distributor Disassembly Cleaning &. Inspecting Distributor Installat ion TYPE D SYSTEM - DISTRIB UTOR CD - POINTLESS Troubleshoo ting Distributor Cleaning &. Inspecting Distributor TYPE msystem - CD COIL PER CYLINDER MODEL MODEL MODEL MODEL Early 1973 MODEL SIN MODEL Late SIN to MODEL MODEL MODEL MODEL MODEL 1500XS (UNITS WITH DISTRIBUTOR) MODEL &. ON MODEL &. ON MODEL &. ON (UNITS WITHOUT DISTRIBUTOR) MODEL 1750 V MODEL 1750 V ONLY MODEL 175 V MODEL 1500 &. 150 V6 SIN AND BELOW MODEL 2000 &. 200 V6 SIN AND BELOW

3 MODEL 200 SIN &: ABOVE 8 POWERHEAD MODEL 225 ALL 6-34 CHAPTER ORGANIZATION 8-1 MODEL -135 SIN A &: ABOVE GENERALPOWERHEAD MODEL 150 SIN &: ABOVE INFORMATION 8-1 MODEL 200 SIN TO MODEL 175 SIN &: ABOVE 6-37 MODEL 250, 275, 300 AND 3.4 LITRE V6 POWERHEADS WITH EFI 7 ELECTRICAL BATTERIES GAUGES AND HORNS Temperature Gauges Warn ing Ughts Fuel Gauges Tachometer Horns ELECTRICAL SYSTEM General Information CHARGING CIRCUIT SERVICE Rectifier Rectifier Installation STATOR SERVICE Installation CHOKE CIRCUIT AND ENRICHENER SYSTEM CRANKING MOTOR CIRCUIT &: Operation - Pinion Gear with Rubber Cushion - Pinion Gear with Snap Ring or Nut - Pinion Gear with Top Spring CRANKING MOTOR REPAIR Testing Parts Cleaning &: Inspecting a Bosch a Delco Remy L6 POWERHEAD and 8-5 Cleaning and Inspecting 8-11 Thermostat Service 8-11 Reed Block Service 8-12 Crankshaft Service 8-13 End Cap Bear ings 8-14 Connecting Rod Service 8-14 Piston Service 8-16 Honing Procedures 8-20 Cylinder Block Service 8-21 &: Installation 8-21 L6 With Oil Injection 8-37 V6 POWERHEAD and 8-35 Crankshaft 8-40 Piston 8-42 End Cap 8-43 Cleaning and Inspecting 8-46 Thermostat Service 8-46 Reed Block Service 8-47 Crankshaft Service 8-48 End Cap Bearings 8-48 Connecting Rod Service 8-48 Piston Service 8-50 Cylinder Block Service 8-51 Honing Procedures Piston &: Rod 8-58 Crankshaft Installation 8-61 Crankcase Cover 8-67 Powerhead Build-up LOWER UNIT DESCRIPTION 9-1 CHAPTER COVERAGE 9-1 TR OUBLESHOOTIN G 9-5 LOWER UNIT REMOVAL ALL UNITS 9-6 Propeller 9-7 WATER PUMP SERVICE and High Pressure Type Pump 9-9 High Volume Type Pump 9-10

4 9 LOWER UNIT (Continued) SERVICING CAM-SHIFT TYPE I UNITS MATCHED WITH EARL Y L6 AND V6 POWERHEADS TO ABOUT 1979 and & Bearing Forward Gear & Bearing Lower Bearing Shift Shaft Forward Gear & Bearing Shimming & Backlash Pinion Gear Depth Forward Gear Backlash & Installation Reverse Gear Backlash SERVICING CAM-SHIFT TYPE II UNITS MATCHED WITH LATE MODEL L6 POWERHEADS FROM ABOUT 1980 AND l50xr4 V6 POWERHEAD 9-35 and Bear ing Carrier Shift Shaft Pinion Gear Forward Gear Pinion Gear Bearing Race Bearing and Installation Bearing Pinion Gear Bearing Race Shift Shaft Forward Gear Pinion Gear Pinion Gear Depth Forward Gear Backlash SERVICING E-Z SHIFT MODELS SINCE ABOUT 1979 Special Word s & Bearing Separate Forward Gear from Bearing Separate Reverse Gear from & Installation Lower Bearing Forward Gear & Bearing Shimming Pinion Gear Depth Forward Gear Backlash Alpha Drive WATER PUMP ASSEMBLING AND INSTALLATION High Pressure Type Pump Shimming (Certain Units) High Volume Type Pump CLEANING AND INSPECTING ALL UNITS LOWER UNIT INSTALLATION Filling Lower Unit & Installation Propeller Installation 10 TRIM/TILT CHAPTER ORGANIZATION MECHANICAL TILT PIN SYSTEM "A" TWO TRIM/TILT CYLINDERS and Operation Special Instructions Bleeding System "A" Cleaning and Inspecting System "A" Service Pump Service Electric Motor Service

5 SYSTEM "B" TWO TRIM CYLINDERS ONE TILT CYLINDER and Operation Bleeding System "B" Flushing System "B" Service Preliminary Tasks Component Service Manual Release Valve Oil Reservoir Cover Trim Cylinder Til t Cylinder Electric Motor Cleaning and Inspecting &: Installation SYSTEM "C" ONE TRIM/TILT CYLINDER and Operation Bleeding System "C" System "C" Service Pump &: Service Cylinder Service 11 REMOTE CONTROLS STEERING SYSTEMS DIRECTIONAL INDICATOR ROTARY STEERING SERVICE Cleaning &: Inspecting STANDARD RIDE GUIDE KIT CUSTOM RIDE GUIDE KITS MERCONTROL PANEL EARLY MODEL COMMANDER CONTROL BOX &: Cleaning &: Inspecting &: Installation CABLE ADJUSTMENTS APPENDIX METRIC CONVERSION CHART ENGINE SPECIFICATIONS AND TUNE-UP ADJUSTMENTS A-I A-3 CARBURETOR JET SIZE/ELEV A TION CHARTS A-13 PISTON AND CYLINDER SPECS. A-19 REED STOP OPENING A-20 LOWER UNIT OIL CAPACITY AND GEAR CHART A-21 LOWER UNIT BACKLASH TABLE A-22 TORQUE VALUE SPECIFICATIONS A-23 WIRE IDENTIFICATION DWGS. L6 Models 900, 950, 1000 and L6 Models 950, 1000, 1100, and L6 Models 1150, 1350, 1400 and L6 Models 900, 11.50, and L6 Models 90, 11.5, and only V6 Models SIN to V6 Models 1.50, 17.5 &: 200 SIN to V6 Models 150,17.5, &: 200 SIN to V6 Models 1.50, 17.5, &: 2,00 SIN to C V6 Model 22.5 SIN and higher 0 V6 Models with 74 block L6 Models 90, 1 j.5, &: V6 Models 135, 1.50, and 175 SIN CI00861 &: higher V6 Mode1150XR4 with 40-amp stator V6 Model 200 WITHOUT EFI SIN CI00861 &: higher V6 Model 220 XRi WITH EFI V6 Model 200 XRi WITH EFI Early V6 remote control WITH temperature horn Early remote control WITH power trim/tilt A-24 A-25 A-26 A-27 A-28 A-29 A-30 A-32 A-34 A-36 A-38 A-40 A-41 A-42 A-43 A-44 A-4.5 A-46 A-47 WITHOUT power trim A-48 WITH power trim/tilt and WITHOUT warning horn A-49 WITH warning horn to 1989 A-.50 WITH warning horn 1989 and on A-.51

6 'WIRE IDENTIFICAnON (Continued) WITH trim indicator gauge and trim sender A-52 Panel mount con trol A-53 Tachometer WITHOUT adjustable dial, trim indicator gauge, and alarm horn A-54 Tachometer WITH adjustable dial, trim indicator gauge and temperature gauge - Model 200 &: 220 WITH EFI only A-55 Instrument panel - single ou tboard installation using "Commander" 2000 remote control A-56 Visual warning system installation A-57 Oil level gauge installation A-58 Dual outboard synchronizer system A-59 Dual outboard instrument setup for PORT outboard uni t A-60 Dual outboard instrument setup for STARBOARD outboard unit A-61 Type "A" power trim/ tilt system - two trim/tilt cylinders -- with OLD style single solenoid A-62 Type "A" power trim/tilt system - two trim/tilt cylinders -- with NEW style single solenoid A-63 Type "A" power trim/tilt system - two trim/tilt cylinders -- with DUAL solenoids A-64 Type "B" power trim/tilt system -- two trim cylinders and one tilt cylinder A-65 Type "C" power trim/tilt system -- WITHOUT fuse - single cylinder - pump mounted in boat A-66 Type "C" power trim/tilt system - WITH fuse - single cylinder -- pump moun ted in boat A-67 Type "C" power trim/ tilt system WITH fuse and on A-68 Trim indicator gauge and alarm horn A-69

TABLE OF CONTENTS 3 POWERHEAD

TABLE OF CONTENTS 3 POWERHEAD TABLE OF CONTENTS 1 SAFETY POWERHEAD SERVICE -- REDESIGNED MODEL (See Listing on Page) 3-27 1-1 3-27 CLEANING, WAXING, &. POLISHING 1-1 3-32 CONTROLLING CORROSION 1-1 3-66 PROPELLERS 1-2 3-48 FUEL SYSTEM