Tle of Contents IMPORTANT INFORMATION Section 1B - Mintennce MAINTENANCE 1 B Specifictions........................... 1B-1 Specil Tools........................... 1B-2 Quicksilver Luricnt/Selnt............. 1B-2 Inspection nd Mintennce Schedule..... 1B-3 Before Ech Use..................... 1B-3 After Ech Use....................... 1B-3 Every 100 Hours of Use............... 1B-3 Every 300 Hours of Use............... 1B-3 Flushing Engine......................... 1B-4 Flushing Cooling System Using Cowl Flush Plug................ 1B-4 Flushing Cooling System Using Flushing Attchment 44357A2.... 1B-4 Fuel System............................ 1B-5 Fuel Line Inspection.................. 1B-5 Wter Seprting Fuel Filter........... 1B-5 Drining Wter from Fuel Filter Chmer on Model 2003 Outords.... 1B-7 Corrosion Control Anode................. 1B-7 Sprk Plug Inspection.................... 1B-8 Bttery Inspection....................... 1B-8 Fuse Replcement...................... 1B-9 Compressor Air intke Filter.............. 1B-10 Removl............................ 1B-10 Instlltion........................... 1B-10 Luriction Points....................... 1B-10 Checking Power Trim Fluid............... 1B-12 Gercse Luriction.................... 1B-13 Storge Preprtion..................... 1B-14 Specifictions FUEL SYSTEM IGNITION SYSTEM STARTING SYSTEM GEAR HOUSING Fuel Recommended Gsoline Recommended Oil Sprk Plug Type Sprk Plug Gp Optionl Sprk Plug Type Sprk Plug Gp Bttery Rting Gercse Cpcity Wter Pressure @ RPM Gsoline with Oil Injection Unleded 87 Octne Minimum TC-W3 Premium Plus or Optimx 2 Cycle Outord Oil NGK IZFR5G 0.8 mm (0.031 in.) NGK PZFR5F-11 1.1 mm (0.043 in.) 1000 (Minimum) Mrine Crnking Amps 750 (Minimum) Cold Crnking Amps 105 (Minimum) Ampere Hours 798.0 ml (27.0 fl. oz.) 55.1-68.9 kp (8-10 psi) minimum @ 5000 RPM 90-859769R03 AUGUST 2003 Pge 1B-1
Specil Tools Grese Gun 91-37299A1 Flushing Attchment 44357A2 Mercury/Quicksilver Luricnts nd Selnts NOTE: Refer to Section 1A for luricnts nd selnts chrt. Pge 1B-2 90-859769R03 AUGUST 2003
Inspection nd Mintennce Schedule MAINTENANCE Before Ech Use After Ech Use 1. Check tht lnyrd stop switch stops the engine. 2. Visully inspect the fuel system for deteriortion or leks. 3. Check outord for tightness on trnsom. 4. Check steering system for inding or loose components. 5. Visully check steering link rod fsteners for proper tightness. 6. Check propeller ldes for dmge. 1. Flush out the outord cooling system if operting in slt or polluted wter. 2. Wsh off ll slt deposits nd flush out the exhust outlet of the propeller nd gercse with fresh wter if operting in slt wter. Every 100 Hours of Use or Once Yerly, Whichever Occurs First 1. Luricte ll luriction points. Luricte more frequently when used in slt wter. 2. Inspect nd clen sprk plugs. 3. Replce wter seprting fuel filter. 4. Replce compressor ir intke filter. 5. Check corrosion control nodes. Check more frequently when used in slt wter. 6. Drin nd replce gercse luricnt. 7. Luricte splines on the drive shft nd shift shft. 8. Check power trim fluid. 9. Inspect ttery. 10. Check control cle djustments. 11. Check tightness of olts, nuts, nd other fsteners. Every 300 Hours of Use or Every Three Yers, Whichever Occurs First 1. Replce wter pump impeller (more often if overheting occurs or reduced wter pressure is noted). 2. Replce the lterntor nd ir compressor drive elts. 3. Replce the two in-line oil filters in the ir compressor oil return lines. 4. These items should e serviced y n uthorized deler. 90-859769R03 AUGUST 2003 Pge 1B-3
Flushing Engine Flushing Cooling System Using Cowl Flush Plug Flush the internl wter pssges of the outord with fresh wter fter ech use in slt, polluted or muddy wter. This will help prevent uildup of deposits from clogging the internl wter pssges. NOTE: Engine cn e stopped or running t idle speed when flushing the cooling system. Do not flush engine using wter system tht exceeds 310.3 kp. (45 psi). 1. Remove the plug from fitting in the ottom cowl. 2. Attch wter hose to the fitting. Turn wter on nd flush for 3 to 5 minutes. Flushing Cooling System Using Flushing Attchment 44357A2 WARNING When flushing, verify tht re in vicinity of propeller is cler nd tht no person is stnding nery to void possile injury. It is recommended to remove propeller s precutionry mesure. IMPORTANT: Front/nose wter inlets must e tped closed when running engine on flush to prevent possile overheting. 1. Instll Quicksilver Flushing Attchment 44357A2 (or equivlent tool) on the ger housing from the FRONT side, positioning the ruer cups over the wter intke openings. 2. Connect hose [12.7 mm (1/2 in.) I.D. or lrger] etween flushing ttchment nd wter tp. IMPORTANT: To prevent wter pump dmge, do not strt or run engine unless cooling wter is flowing. 3. With the outord in the norml operting position (verticl), prtilly open wter tp (IT IS NOT NECESSARY to use full wter pressure) nd djust wter flow so tht there is significnt wter loss round the ruer cups. 4. Strt engine nd idle in NEUTRAL. Increse engine speed, not to exceed 2500 RPM. 5. Flush or service engine s required. Verify dequte cooling wter is provided.. Wter must e dischrged through tell tle IMPORTANT: Prevent engine overheting. If wter flow is insufficient, stop engine nd determine cuse efore continuing.. Flush until dischrge wter is cler. In slt wter res, run outord 3 to 5 minutes. c. Stop engine efore turning off wter. 6. Stop engine, turn wter off nd remove flushing ttchment from ger housing. IMPORTANT: During nd fter flushing, keep outord in upright position until ll wter hs drined from drive shft housing to prevent wter from entering the powerhed vi drive shft housing nd exhust ports. Pge 1B-4 90-859769R03 AUGUST 2003
Fuel System MAINTENANCE Fuel Line Inspection WARNING Avoid serious injury or deth from gsoline fire or explosion. Crefully follow ll fuel system service instructions. Alwys stop the engine nd DO NOT smoke or llow open flmes or sprks in the re while servicing ny prt of the fuel system. Before servicing ny prt of the fuel system, stop engine nd disconnect the ttery. Drin the fuel system completely. Use n pproved continer to collect nd store fuel. Wipe up ny spillge immeditely. Mteril used to contin spillge must e disposed of in n pproved receptcle. Any fuel system service must e performed in well ventilted re. Inspect ny completed service work for sign of fuel lekge. Visully inspect the fuel line nd primer ul for crcks, swelling, leks, hrdness, or other signs of deteriortion or dmge. If ny of these conditions is found, the fuel line or primer ul must e replced. Wter Seprting Fuel Filter NOTE: The wrning system will turn on when wter in the fuel filter reches the full level. 1. This filter removes moisture nd lso deris from the fuel. If the filter or filter chmer ecomes filled with wter, the wter cn e removed. If the filter ecomes plugged with deris, the filter must e replced with new filter. 2. Remove nd replce filter s follows:. Turn ignition key switch to OFF position.. Disconnect wire t ottom of filter. c. Unscrew filter. Tip the filter to drin fluid into suitle continer. d. Luricte the seling ring on the filter with oil. Thred on the filter nd tighten securely y hnd. Reconnect the wire to the filter. 57792 2000/2001/2002 2003 nd newer IMPORTANT: Visully inspect for fuel lekge from the filter y squeezing the primer ul until firm, forcing fuel into the filter. 90-859769R03 AUGUST 2003 Pge 1B-5
Model 2003 Mechnicl Shift Remove nd replce filter s follows: e. Disconnect link rod. f. Use the shft of screwdriver etween the lugs on the filter cp nd unscrew the filter. g. Luricte the O-ring sels with oil. h. Instll the fuel filter nd tighten securely. i. Reconnect the link rod. c -Link rod -Filter c -Sels IMPORTANT: Visully inspect for fuel lekge from the filter y squeezing the primer ul until firm, forcing fuel into the filter. Model 2003 Digitl Throttle nd Shift Remove nd replce filter s follows: j. Use the shft of screwdriver etween the lugs on the filter cp nd unscrew the filter. k. Luricte the O-ring sels with oil. l. Instll the fuel filter nd tighten securely. -Filter -Sels IMPORTANT: Visully inspect for fuel lekge from the filter y squeezing the primer ul until firm, forcing fuel into the filter. Pge 1B-6 90-859769R03 AUGUST 2003
Drining Wter from Fuel Filter Chmer on Model 2003 Outords MAINTENANCE NOTE: If sufficient mount of wter hs ccumulted in the fuel filter chmer, the wrning system will turn on. Drining the wter from the fuel filter chmer is required. 1. Pull the drin hose off the right side fitting. Hold the open end of the hose over continer. Loosen drin screw nd drin the fuel filter chmer. Re-tighten drin screw nd rettch hose. IMPORTANT: Visully inspect for fuel lekge from the drin screw y squeezing the primer ul until firm, forcing fuel into the chmer. c -Drin hose -Fitting c -Drin screw Corrosion Control Anode The gercse hs two corrosion control nodes, one on ech side. Another node is instlled on the ottom of the trnsom rcket ssemly. An node helps protect the outord ginst glvnic corrosion y scrificing its metl to e slowly eroded insted of the outord metls. Ech node requires periodic inspection especilly in slt wter which will ccelerte the erosion. To mintin this corrosion protection, lwys replce the node efore it is completely eroded. Never pint or pply protective coting on the node s this will reduce effectiveness of the node. 90-859769R03 AUGUST 2003 Pge 1B-7
Sprk Plug Inspection Inspect sprk plugs t the recommended intervls. 1. Remove the sprk plug leds y twisting the ruer oots slightly nd pull off. Inspect sprk plug oots nd replce if crcked. 2. Remove the sprk plugs to inspect nd clen. Replce sprk plug if electrode is worn or the insultor is rough, crcked, roken, listered or fouled. 3. Set the sprk plug gp. See Specifiction Chrt in Generl Informtion Section. Bttery Inspection 4. Before reinstlling sprk plugs, clen wy dirt on the sprk plug sets. Instll plugs finger tight, nd tighten 1/4 turn or tighten to 27 Nm (20 l-ft). The ttery should e inspected t periodic intervls to ensure proper engine strting cpility. IMPORTANT: Red the sfety nd mintennce instructions which ccompny your ttery. 1. Turn off the engine efore servicing the ttery. 2. Add wter s necessry to keep the ttery full. 3. Mke sure the ttery is secure ginst movement. 4. Bttery cle terminls should e clen, tight, nd correctly instlled. Positive to positive nd negtive to negtive. 5. Mke sure the ttery is equipped with nonconductive shield to prevent ccidentl shorting of ttery terminls. Pge 1B-8 90-859769R03 AUGUST 2003
Fuse Replcement MAINTENANCE IMPORTANT: Alwys crry spre SFE 15 nd SFE 20 AMP fuses. Wiring circuits on the outord re protected from overlod y fuses. If the silver nd is roken, the fuse is lown. If fuse is lown, locte nd correct the cuse of the overlod. If the cuse is not found, the fuse my low gin. Alwys replce lown fuse with new fuse hving the sme rting. The fuses nd circuits re identified s follows: 1. Model 2000/2001. ECM Driver Power/Oil Pump Circuit SFE 20 Ampere Fuse.. Accessories SFE 20 Ampere Fuse. c. Ignition Coil Circuit SFE 20 Ampere Fuse. d. Electric Fuel Pump Circuit SFE 20 Ampere Fuse. 2. Model 2002/2003 Mechnicl Shift. SmrtCrft Dt Bus Circuit SFE 15 Ampere Fuse.. Accessories SFE 20 Ampere Fuse. c. Ignition Coil Circuit SFE 20 Ampere Fuse. d. Electric Fuel Pump, ECM Driver Power, Oil Pump Circuit SFE 20 Ampere Fuse. 3. Model 2003 Digitl Throttle nd Shift. Not Used.. Depth Finder nd Accessories SFE 2 Ampere Fuse. c. Ignition System SFE 20 Ampere Fuse. d. Fuel Injector, Direct Injector, Strter Slve Solenoid, PCM nd Electric Fuel Pumps SFE 20 Ampere Fuse. 20 2000/2001 57778 d c d 15 2002/2003 Mechnicl c 57494 d 2 2003 nd Newer Digitl c 90-859769R03 AUGUST 2003 Pge 1B-9
Compressor Air intke Filter The filter should e chnged every 100 hours of opertion, or once seson. Never run the engine without the ir filter. Removl 1. Remove flywheel cover from the engine. Remove cover nd filter. Unlock Lock 2000/2001/2002 2003 -Flywheel cover -Filter Instlltion Instll filter into the cover. Fsten cover with 4 screws. Apply Loctite 271 to screw threds. Luriction Points 1. Luricte the following points with Specil Luricnt 101. Trim Rod Bll Ends Turn the ll ends to work the luricnt into the ll sockets. Pge 1B-10 90-859769R03 AUGUST 2003
2. Luricte the following with Anti-Corrosion Grese or 2-4-C with Teflon. Propeller Shft Refer to Propeller Replcement for removl nd instlltion of the propeller. Cot the entire propeller shft with luricnt to prevent the propeller hu from corroding nd seizing to the shft. 3. Luricte the following with 2-4-C with Teflon or Specil Luricnt 101. Swivel Brcket Luricte through fitting. Tilt Support Lever Luricte through fitting. Tilt Tue Luricte through fitting. 57834 90-859769R03 AUGUST 2003 Pge 1B-11
Steering Cle Grese Fitting (If Equipped) Rotte steering wheel to fully retrct the steering cle end () into the outord tilt tue. Luricte through fitting (). WARNING The end of the steering cle must e fully retrcted into the outord tilt tue efore dding luricnt. Adding luricnt to steering cle when fully extended could cuse steering cle to ecome hydruliclly locked. A hydruliclly locked steering cle will cuse loss of steering control, possily resulting in serious injury or deth. Luricte Points 7 With Light Weight Oil. Steering Link Rod Pivot Points Luricte pivot points. Checking Power Trim Fluid 1. Tilt outord to the full up position nd engge the tilt support lock. 2. Remove fill cp nd check fluid level. The fluid level should e even with the ottom of the fill hole. Add Power Trim & Steering Fluid. If not ville, use utomotive (ATF) utomtic trnsmission fluid. Pge 1B-12 90-859769R03 AUGUST 2003
Gercse Luriction MAINTENANCE DRAINING GEARCASE When dding or chnging gercse luricnt, visully check for the presence of wter in the luricnt. If wter is present, it my hve settled to the ottom nd will drin out prior to the luricnt, or it my e mixed with the luricnt, giving it milky colored ppernce. If wter is noticed, hve the gercse checked y your deler. Wter in the luricnt my result in premture ering filure, or in freezing tempertures, will turn to ice nd dmge the gercse. NOTE: Some models my hve the vent nd fill/drin plugs on the opposite side. 1. Plce outord in verticl operting position. 2. Plce drin pn elow outord. 3. Remove vent plug nd fill/drin plug nd drin luricnt. c -Drin pn -Fill/drin plug c -Vent plug GEARCASE LUBRICANT CAPACITY Gercse luricnt cpcity is pproximtely 798.0 ml (27 fl. oz.). CHECKING GEARCASE LUBRICANT LEVEL AND REFILLING GEARCASE NOTE: Some models my hve the vent nd fill/drin plugs on the opposite side. 1. Plce outord in verticl operting position. 2. Remove vent plug. 90-859769R03 AUGUST 2003 Pge 1B-13
3. Plce luricnt tue into the fill hole nd dd luricnt until it ppers t the vent hole. IMPORTANT: Replce seling wshers if dmged. 4. Stop dding luricnt. Instll the vent plug nd seling wsher efore removing the luricnt tue. 5. Remove luricnt tue nd reinstll clened fill/drin plug nd seling wsher. c -Vent plug nd seling wsher -Luricnt tue d c -Vent hole d-fill/drin plug nd seling wsher Storge Preprtion The mjor considertion in prepring your outord for storge is to protect it from rust, corrosion, nd dmge cused y freezing of trpped wter. The following storge procedures should e followed to prepre your outord for out of seson storge or prolonged storge (two months or longer). CAUTION Never strt or run your outord (even momentrily) without wter circulting through ll the cooling wter intke holes in the gercse to prevent dmge to the wter pump (running dry) or overheting of the engine. FUEL SYSTEM IMPORTANT: Gsoline contining lcohol (ethnol or methnol) cn cuse formtion of cid during storge nd cn dmge the fuel system. If the gsoline eing used contins lcohol, it is dvisle to drin s much of the remining gsoline s possile from the fuel tnk, remote fuel line, nd engine fuel system. Fill the fuel system (tnk, hoses, fuel pumps, nd fuel injection systems) with treted (stilized) fuel to help prevent formtion of vrnish nd gum. Proceed with following instructions. 1. Portle Fuel Tnk Pour the required mount of Gsoline Stilizer (follow instructions on continer) into fuel tnk. Tip fuel tnk ck nd forth to mix stilizer with the fuel. 2. Permnently Instlled Fuel Tnk Pour the required mount of Gsoline Stilizer (follow instructions on continer) into seprte continer nd mix with pproximtely one qurt (one liter) of gsoline. Pour this mixture into fuel tnk. 3. Remove the wter seprting fuel filter from engine. Empty the fuel into suitle continer nd discrd the filter properly. Pge 1B-14 90-859769R03 AUGUST 2003
4. Premix the following in continer: 8cc (0.27 oz) or 2 tespoons of Quickleen Engine Tretment. 8cc (0.27 oz) or 2 tespoons of Fuel Stilizer. 5. Pour this mixture in new wter seprtor fuel filter on Model Yer 2000/2001/2002. Reinstll the fuel filter. On Model Yer 2003 nd newer, remove fuel wter seprtor filter nd pour mixture into vpor seprtor tnk. Reinstll fuel wter seprtor filter. 6. Prime the fuel system s outlined in the Strting Procedure. 7. Plce the outord in wter or connect flushing ttchment for circulting cooling wter. Run the engine t idle speed for 10 minutes to llow treted fuel to fill the fuel system. PROTECTING INTERNAL ENGINE COMPONENTS NOTE: Mke sure the fuel system hs een prepred for storge. 1. Remove the sprk plugs nd dd pproximtely 30ml (one ounce) of engine oil into ech sprk plug hole. Rotte the flywheel mnully severl times to distriute the oil in the cylinders. Reinstll sprk plugs. PROTECTING EXTERNAL OUTBOARD COMPONENTS 1. Luricte ll outord components listed in the Inspection nd Mintennce Schedule. 2. Touch up ny pint nicks. See your deler for touch-up pint. 3. Spry Corrosion Gurd on externl metl surfces (except corrosion control nodes). GEARCASE Drin nd refill the gercse luricnt (refer to mintennce procedure). POSITIONING OUTBOARD FOR STORAGE Store outord in n upright (verticl) position to llow wter to drin out of outord. CAUTION If outord is stored tilted up in freezing temperture, trpped cooling wter or rin wter tht my hve entered the propeller exhust outlet in the gercse could freeze nd cuse dmge to the outord. BATTERY STORAGE 1. Follow the ttery mnufcturers instructions for storge nd rechrging. 2. Remove the ttery from the ot nd check wter level. Rechrge if necessry. 3. Store the ttery in cool, dry plce. 4. Periodiclly check the wter level nd rechrge the ttery during storge. 90-859769R03 AUGUST 2003 Pge 1B-15