SPECIFICATIONS

IMPORTANT INFORMATION 1
Section 1A - Specifications A
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Mercury/Quicksilver Lubricants
Propeller Information Charts . . . . . . . . . . . . . . 1A-9 and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-10
Torque Specifications . . . . . . . . . . . . . . . . . . . . 1A-12

Specifications

Models 115 EFI (4-Stroke)

Horsepower:
Model 115 115 hp (85.8 Kw) @ 5500 rpm
PERFORMANCE Wide Open Throttle (WOT) rpm
Range 5000 - 6000
OUTBOARD Electric
WEIGHT 115 EFI ELPT 386 lb (175 kg)
Recommended Gasoline Automotive Unleaded
FUEL with a Minimum Pump Posted
Octane Rating of 87
Oil Filter p/n 35-822626A2
Oil Filter Wrench p/n 91-802653Q1
Engine Oil Capacity Either 5 Quarts or 5 Liters
Engine Oil SAE 10W-30 viscosity oil is recom-
mended for use in all temperatures.
SAE SAE SAE 25W-40 viscosity oil may be used
F° C° 25W-40 10W-30 at temperatures above 40° F (4° C).

+100 +38 Use Mercury/Quicksilver 4-Cycle Ma-

+80 +27 rine Oil with the proper viscosity for the
OIL expected temperature in your area (see
+60 +16 range thermometer on left). If not avail-
+40 +4 able, use a premium quality 4-cycle en-
gine oil certified to meet or exceed any
+20 –7 one of the following American Petro-
–18 leum Institute (API) service classifica-
0
tions SH, SG, SF, CF-4, CE, CD, CDll.

90-881980R1 NOVEMBER 2001 Page 1A-1

SPECIFICATIONS

Type Microcomputer-ECM
Spark Plug:
Type NGK LFR6A-11
Gap 0.039 - 0.043 in. (1.0 - 1.1 mm)
Hex Size 5/8 in. (16 mm)
Torque 18 lb-ft (25 Nm)
Hole Size 14 mm
Firing Order 1-3-4-2
Ignition Timing:
@ Idle (750 rpm) in Neutral 4° A.T.D.C
@ WOT (6000 rpm) 20° B.T.D.C
Stator Coil Output - Peak Voltage:
@ 400 rpm (Cranking) 10 - 18 V
@ 750 rpm (Idle) 16 - 24 V
@ 1500 rpm 16 - 24 V
@ 3500 rpm 16 - 24 V
Stator Coil Resistance 0.2 - 0.8 Ω
Crank Position Sensor - Peak Voltage:
@ 400 rpm (Cranking) 3.0 -6.3 V
@ 750 rpm (Idle) 9 - 16 V
@ 1500 rpm 18 - 28 V
@ 3500 rpm 35 - 55 V
Crank Position Sensor Resistance 445 - 565 Ω
IGNITION ECM (Coil Primary) - Peak Voltage:
SYSTEM @ 400 rpm (Cranking) 180 - 320 V
Readings taken @ @ 750 rpm (Idle) 180 - 235 V
68°F (20°C). @ 1500 rpm 230 -290 V
@ 3500 rpm 280 - 340 V
Ignition Coil Resistance
Primary 1.8 - 2.6 Ω
Secondary (Between Boots)
Coil for Cylinders 1 & 4 18.97 - 35.23 kΩ
Coil for Cylinders 2 & 3 18.55 - 34.45 kΩ
Engine Protection Controls:
Engine Speed Limiter
Spark Cut-Out to Cylinders
#1 or #4 6200 rpm
#1 and #4 6250 rpm
#1, #4, and #2 or #3 6350 rpm
#1, #2, #3, and #4 6450 rpm
Overheat/Low Oil Pressure Engine
Speed Control (Spark Cut-Out to
Cylinders #1 and #4). Gradually Lowers to 2000 rpm
Water Temperature Sensor:
Warning Horn/rpm Reduction. 194°F (90°C)
Reset Temperature and Closed
Throttle. 167°F (75°C)
Engine Oil Pressure Switch:
Warning Horn/rpm Reduction Continuity Below 21.78 psi (150 kPa)

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 SPECIFICATIONS

Reset Pressure and Closed

Throttle. No Continuity Above 21.78 psi (150 kPa)
Engine Water Temperature Sensor
IGNITION Resistance:
SYSTEM @ 41°F (5°C) 4.62 kΩ
Readings taken @ @ 68°F (20°C) 2.44 kΩ
68°F (20°C). @ 212°F (100°C) 0.19 kΩ
Throttle Position Sensor (TPS):
Input Voltage @ Idle (750 rpm) 5.0 ± 0.25 V
Output Voltage@ Idle (750 rpm) 0.718 - 0.746 V
Alternator Type: Three Phase Stator Coil (12 Pole)
Alternator Output 12.0 V; 25 Amps. (300 Watts)
(Rectified/Regulated)
Stator Coil - Peak Voltage:
@ 400 rpm (Cranking) 10 - 18 V
CHARGING @ 750 rpm (Idle) 16 - 24 V
SYSTEM @ 1500 rpm 16 - 24 V
Readings taken @ @ 3500 rpm 16 - 24 V
68°F (20°C). Stator Coil Resistance 0.2 - 0.8 Ω
Rectifier/Regulator Output - Peak
Voltage:
@ 750 rpm (Idle) 12.5 - 15.5 V
@ 1500 rpm 13.0 - 16.0 V
@ 3500 rpm 13.0 - 16.0 V
Quicksilver Tachometer Setting “6P” or “4”
Electric Start:
Starter Type Sliding Gear
Model/Manufacturer S114-838A/Hitachi
Output 1.4 kW - 12 V
Rating 30 Seconds
Reduction Gear Ratio 7.85 (102:13)
Brush:
Length 0.610 in. (15.5 mm)
STARTING
Minimum Length 0.374 in. (9.5 mm)
SYSTEM
Commutator:
Diameter 1.113 in. (29.0 mm)
Minimum Diameter 1.100 in. (28.0 mm)
Undercut 0.020 in. (0.5 mm)
Undercut Limit 0.008 in. (0.2 mm)
Ampere Draw Under:
(Load) 165 Amps
(No Load) 80 Amps
Battery Rating
Minimum Requirement 465 Marine Cranking Amps (MCA)
or 350 Cold Cranking Amps (CCA)
BATTERY
For operation below 32° F (0° C) 1000 Marine Cranking Amps (MCA) or
775 Cold Cranking Amps (CCA)
Ampere-Hours (Ah) 70 - 100
Fuel Pump Type External (Plunger/Diaphragm)
Fuel Pump:
FUEL Discharge (@ 3000 rpm) 17 gph (65 L/h)
SYSTEM Pressure (Maximum) 7 psi (49 kPa)
Plunger Stroke 0.23 - 0.36 in. (5.85 - 9.05 mm)
Fuel Tank Capacity Accessory

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SPECIFICATIONS

Fuel Injection System Batch (1 & 4) - (2 & 3)

Idle rpm (In Neutral) Warm 750 ± 50 rpm
FUEL INJECTION
Idle rpm (In Forward Gear) Warm 700 ± 50 rpm
Fuel Pressure @ 1500rpm 41-44 psi (283-304 kPa)
Type In–Line, 4 Stroke – DOHC, 16 Valves
CYLINDER
Displacement 106.2 cid (1,741 cc)
BLOCK
Number of Cylinders 4
STROKE Length 3.496 in. (88.8 mm)
Diameter
Standard 3.110 - 3.111 in. (79.000 - 79.020 mm)
CYLINDER
Oversize-0.010 in. (0.25 mm) 3.120 - 3.121 in. (79.250 - 79.270 mm)
BORE
Taper/Out of Round Maximum 0.003 in. (0.08 mm)
Bore Type Cast Iron
Piston Type Aluminum
Measure Point (H) 0.51 in. (13 mm)
O.D. at Skirt (H)
Standard (D) 3.1074 - 3.1082 in. (78.928 - 78.949 mm)
Oversize-0.010 in. (0.25 mm) 3.1174 - 3.1182 in. (79.178 - 79.199 mm)

PISTON Pin Boss Inside Diameter 0.7090 - 0.7093 in. (18.008 - 18.015 mm)

H
D
PISTON Piston to Cylinder Clearance 0.0028 - .0031 in. (0.070 - 0.080 mm)
CLEARANCE

Top Ring
Dimension “B” B 0.046 - 0.047 in. (1.17 - 1.19 mm)
Dimension “T” 0.114 - 0.115 in. (2.89 - 2.91 mm)
End Gap (Installed) T 0.006 - 0.012 in. (0.15 - 0.30 mm)
Side Clearance 0.001 - 0.003 in. (0.03 - 0.08 mm)
Middle Ring
Dimension “B” 0.058 - 0.059 in. (1.47 - 1.49 mm)
Dimension “T” 0.118 - 0.126 in. (3.00 - 3.20 mm)
RINGS B 0.028 - 0.035 in. (0.70 - 0.90 mm)
End Gap (Installed)
Side Clearance 0.001 - 0.003 in. (0.03 - 0.08 mm)
Bottom (Oil Ring)
T
Dimension “B” 0.094 - 0.098 in. (2.38 - 2.48 mm)
Dimension “T” 0.094 in. (2.40 mm)
End Gap (Installed) 0.008 - 0.028 in. (0.20 - 0.70 mm)
Side Clearance B 0.001 - 0.006 in. (0.03 - 0.15 mm)

T
COMPRESSION Compression Ratio 9.7:1
RATIO Cylinder Compression (Minimum) 138 psi (950 kPa)
PISTON PIN Piston Pin Outside Diameter 0.7085 - 0.7087 in. (17.997 - 18.000 mm)

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 SPECIFICATIONS

Small End Inside Diameter 0.7073 - 0.7081 in. (17.965 - 17.985 mm)
Big End Inside Diameter 1.7726 - 1.7734 in. (45.025 - 45.045 mm)
Oil Clearance (Big End) 0.0010 - 0.0012 in. (0.025 - 0.031 mm)
CONNECTING Big End Bearing Thickness
ROD Yellow 0.0591 - 0.0594 in. (1.502 -1.508 mm)
Green 0.0594 - 0.0596 in. (1.508 - 1.514 mm)
Blue 0.0596 - 0.0598 in. (1.514 - 1.520 mm)
Red 0.0598 - 0.0601 in. (1.520 - 1.526 mm)
Crankshaft Journal
Diameter 1.8891 - 1.8898 in.
(47.984 - 48.000 mm)
Minimum Diameter 1.8887 in. (47.972 mm)
Crankshaft Pin
Diameter 1.6535 - 1.6528 in.
(42.000 - 41.982 mm)
CRANKSHAFT Minimum Diameter 1.7311 in. (43.971 mm)
Crankshaft Run-out 0.001 in. (0.03 mm)

Crankcase Main Journal Inside

Diameter 2.1269 - 2.1276 in.
(54.023 - 54.042 mm)
Crankshaft Journal Oil Clearance 0.0009 - 0.0017 in. (0.024 - 0.044 mm)
Upper Crankcase Main Journal
Bearing Thickness
Green 0.1178 - 0.1181 in. (2.992 - 2.999 mm)
Blue 0.1181 - 0.1183 in. (2.999 - 3.006 mm)
Red 0.1183 - 0.1186 in. (3.006 - 3.013 mm)
CRANKCASE Lower Crankcase Main Journal
Bearing Thickness
Yellow 0.1185 -0.1188 in. (3.010 - 3.017 mm)
Green 0.1188 - 0.1191 in. (3.017- 3.024 mm)
Blue 0.1191 - 0.1193 in. (3.024 - 3.031 mm)
Red 0.1193 - 0.1196 in. (3.031 - 3.038 mm)
No. 3 Main Journal Bearing Thickness
Green 0.1178 - 0.1181 in. (2.992 - 2.999 mm)
Blue 0.1181 - 0.1183 in. (2.999 - 3.006 mm)
Red 0.1183 - 0.1186 in. (3.006 - 3.013 mm)

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SPECIFICATIONS

Camshaft Dimensions
Intake “A” 1.465 - 1.472 in. (37.22 - 37.38 mm)
Exhaust “A” 1.453 - 1.459 in. (36.90 - 37.06 mm)
Intake “B” A 1.178 - 1.184 in. (29.92 - 30.08 mm)
Exhaust “B” 1.178 - 1.184 in. (29.92 - 30.08 mm)
Valve Lift
Intake 0.287 in. (7.30 mm)
Exhaust B 0.275 in. (6.98 mm)
CAMSHAFT Run-out Limit 0.004 in. (0.1 mm)
Camshaft Bearing Diameter “a” 0.9827 - 0.9835 in. (24.96 - 24.98 mm)
Camshaft Bearing Oil Clearance 0.0008-0.0024 in.(0.020-0.061 mm)

A
Free Length “a” 2.094 in. (53.20 mm)
Minimum Free Length 2.057 in. (52.25 mm)
Tilt Limit “b” Less than 0.10 in. (2.6 mm)
b

VALVE SPRING
a

Warp Limit 0.004 in. (0.1 mm)

CYLINDER HEAD
Camshaft Bearing Inside Diameter 0.984 - 0.985 in. (25.000 - 25.021 mm)

Valve Lifter Bore Inside Diameter 1.102 - 1.103 in. (28.000 - 28.021 mm)

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 SPECIFICATIONS

Valve/Valve Seat/Valve Guides:

Valve Clearance (cold)
Intake 0.007 - 0.009 in. (0.17 - 0.23 mm)
Exhaust 0.012 - 0.014 in. (0.31 - 0.37 mm)

Valve Face Angle

Intake 120°, 91°, 110°
Exhaust 140°, 91°, 110°
Valve Dimensions:
“A” Head Diameter
Intake 1.142 - 1.150 in. (29.00 - 29.20 mm)
Exhaust 0.945 - 0.953 in. (24.00 - 24.20 mm)
“B” Face Width
Intake 0.078 - 0.094 in. (1.98 - 2.40 mm)
Exhaust 0.089 - 0.106 in. (2.26 - 2.69 mm)
“C” Seat Width
Intake 0.062 - 0.076 in. (1.58 - 1.94 mm)
VALVES Exhaust 0.071 - 0.080 in. (1.80 - 2.02 mm)
“D” Margin Thickness
Intake 0.031 - 0.047 in. (0.80 - 1.20 mm)
Exhaust 0.039 - 0.055 in. (1.00 - 1.40 mm)
Stem Outside Diameter
Intake 0.2352 - 0.2358 in. (5.975 - 5.990 mm)
Exhaust 0.2346 - 0.2352 in. (5.960 - 5.975 mm)
Guide Inside Diameter
Intake 0.2364 - 0.2369 in. (6.005 - 6.018 mm)
Exhaust 0.2364 - 0.2369 in. (6.005 - 6.018 mm)
Stem To Guide Clearance
Intake 0.0006 - 0.0017 in. (0.015 - 0.043 mm)
Exhaust 0.0012 - 0.0023 in. (0.030 - 0.058 mm)
Stem Run-out Limit (max.) 0.001 in. (0.03 mm)

Valve Dimensions

“C”
“B”
“D”
“A”
Head Diameter Face Width Seat Width Margin Thickness

Valve Lifter Outside diameter 1.1010 - 1.1016 in.

VALVE LIFTERS (27.965 - 27.980 mm)
Valve Lifter to Lifter Bore Clearance 0.0008 - 0.0022 in. (0.020 -0.056 mm)
Valve shim Thickness 0.0787 - 0.1299 in. (2.000 - 3.300 mm)
VALVE SHIM
(in 0.025 mm increments)
Valve Opening Temperature 122° F (50° C)
THERMOSTAT Full Open Temperature 140° F (60° C)
Valve Lift (Minimum) 0.17 in. (4.3 mm)

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SPECIFICATIONS

Pump Type Trochoid with Relief Valve

Oil Pump Drive Drive shaft Spline
Discharge at 212°F (100°C) with
10W-30 Oil at 1000 rpm 1.56 gph (5.9 L/h)
LUBRICATION Engine Oil Pressure (Warm Engine)
SYSTEM @ 750 rpm 50.75 psi (350 kPa)
Engine Oil Pan Capacity Either 5 Qts. or 5 Liters
Relief Valve Opening Pressure 71 psi (490 kPa)
Oil Pump:
Non-Serviceable
Recommended Transom Height:
Short Shaft 20 in. (51 cm)
Long Shaft 25 in. (64 cm)
MID-SECTION
Steering Pivot Range 60°
Full Tilt Up Angle 71°
Allowable Transom Thickness (Max) 3 in. (76.2 mm)
Gear Ratio 2.07:1
Gearcase Capacity 24 fl oz (710 mL)
Lubricant Type Premium Gear Lubricant
Forward Gear
Number of Teeth 29 Spiral/Bevel
Pinion Gear
Number of Teeth 14 Spiral/Bevel
GEAR HOUSING Pinion Height 0.025 in. (0.64 mm)
BIGFOOT Pinion Gear Locating Tool 91-12349A2
(2.07:1) Flat Number #2
Disc Number #3
Forward Gear Backlash 0.015-0.022 in. (0.38-0.55 mm)
Backlash Indicating Tool 91-19660--1
Mark Number #1
Water Pressure
@ 1000 rpm 5 psi (34.5 kPa)
@ 6000 rpm (WOT) 20.5 psi (141.5 kPa)

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 SPECIFICATIONS

Propeller Information Charts

Mercury/Mariner 115 EFI (4-Stroke) 2.07:1

Wide Open Throttle RPM : 5000-6000
Recommended Transom Heights : 20 in. (50.8 cm), 25 in. (63.5 cm)
Right Hand Rotation Standard
Gear Reduction : 2.07:1

Approx. Approx. Speed

No. of Gross Boat Boat Range Propeller
Diameter Pitch Blades Material Wgt. (lbs) Length (mph) Part Number
13-1/2″ 26″ 3 Steel Up to 1700 Up to 17′ 51-67 48-16996A45
13-1/2″ 24″ 3 Steel Up to 2000 Up to 18′ 45-60 48-16994A45
12-1/2″ 23″ 3 Alum 1700-2400 16-18′ 43-57 48-77350A45
13-1/2″ 22″ 3 Steel 1800-2600 16-18′ 40-54 48-16992A45
12-3/4″ 21″ 3 Alum 2000-2800 16-19′ 38-51 48-77348A45
13-1/4″ 20″ 3 Steel 2100-3100 17-19′ 36-48 48-16990A45
13″ 19″ 3 Alum 2300-3400 17-19′ 33-45 48-77346A45
13″ 18″ 3 Steel 2500-3700 18-20′ 31-42 48-16988A45
13-1/4″ 17″ 3 Alum 2800-4100 18-21′ 29-39 48-77344A45
13-1/8″ 16″ 3 Steel 3100-4500 19-22′ 26-36 48-16986A45
13-1/4″ 16″ 3 Alum 3100-4500 19-22′ 26-36 48-85360A45
13-3/4″ 15″ 3 Alum 3400-5000 19-23′ 24-33 48-77342A45
13-3/8″ 14″ 3 Steel 3800-5700 21-25′ 22-30 48-17314A45
14″ 13″ 3 Alum 4200-6400 22-26′ 20-28 48-77340A45
14″ 12″ 3 Steel 5000+ pontoon 17-24 48-17312A45
14″ 11″ 3 Alum 6000+ pontoon/work 15-21 48-77338A45
14″ 10″ 3 Steel 8000+ houseboat/ 1-19 48-17310A45
work

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SPECIFICATIONS

Mercury/Quicksilver Lubricants and Sealants

Description Mercury Part Number Quicksilver Part Number
Needle Bearing Assy. Lubricant
92-802868A1 N/A
[8 oz. (226.8 grams)] tube
Dielectric Grease
92-823506-1 92-823506-1
[8 oz. (226.8 grams)] can
Loctite 271 – Thread Locker
92-809819 92-809819
(10 ml) tube
Loctite 567 PST Pipe Sealant
92-809822 92-809822
(50 ml) tube
Loctite Master Gasket Kit 92-12564-2 92-12564-2
2 Cycle Premium Outboard Oil
92-802815A1 92-802815Q1
[1 Gallon (3.7 liter)]
Perfect Seal
92-34227-1 92-34227-1
[16 oz. (0.45 kg)] can
Liquid Neoprene
92-25711-3 92-25711-3
[8 oz. (226.8 grams)] can
Cyanacrylate Adhesive Obtain Locally Obtain Locally
Bellows Adhesive N/A 92-86166Q1
Loctite 680 Retaining Compound
92-809833 92-809833
(10 ml) tube
Loctite 222 Thread Locker
92-809818 92-809818
(10 ml) tube
3M Permabond #3M08155 Obtain Locally Obtain Locally
Loctite 242 Thread Locker
92-809821 92-809821
(10 ml) tube
Loctite 609 Obtain Locally Obtain Locally
Loctite 405 Obtain Locally Obtain Locally

Page 1A-10 90-881980R1 NOVEMBER 2001

 SPECIFICATIONS

Description Mercury Part Number Quicksilver Part Number

RTV 587 Silicone Sealer

92-809825 92-809825
[3 oz. (85.05 grams)]

Loctite 262 Obtain Locally Obtain Locally

Premium Gear Lubricant

92-802846A1 92-802846Q1
[1 Quart (0.94 liter)]

Loctite 7649 Primer

92-809824 92-809824
[4.5 oz (127.57 grams)]

Anti-Corrosion Grease
92-802867A1 92-802867Q1
[8 oz. (226.8 grams)] tube

2-4-C with Teflon

92-802859A1 92-802859Q1
[8 oz. (226.8 grams)] tube

Loctite Quick Tite Obtain Locally Obtain Locally

Isopropyl Alcohol Obtain Locally Obtain Locally

Hot Glue Obtain Locally Obtain Locally

Special Lubricant 101

92-802865A1 92-802865Q1
[8 oz. (226.8 grams)] tube

4 Stroke 10W30 Outboard Oil

92-802833A1 92-802833Q1
[1 Quart (0.94 liter)]

4 Cycle 25W40 Engine Oil

92-802837A1 92-802837Q1
[1 Quart (0.94 liter)]

Power Trim & Steering Fluid

92-802880A1 92-802880Q1
[8 oz. (226.8 grams)]

Engine Coupler Spline Grease

92-802869A1 92-802869Q1
[14 oz. (0.39 kg)] cartridge

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SPECIFICATIONS

Torque Specifications
Fastener Location DIameter x Torque
Length (mm) lb-in. lb-ft. Nm
ELECTRICAL
Flywheel
Cover Screw M6 x 20 70 8
Stator Screw M6 x 28 70 8
Flywheel Nut N/A 140 190
Belt Tensioner Screw N/A 29 40
Ignition Components
Crank Position Sensor Mounting Screw N/A 43 5
Voltage Regulator/Rectifier M6 x 25 70 8
Mounting Screw
ECM Mounting Screw M6 x 28 70 8
Coil Mounting Screw M6 x 25 70 8
Spark Plug Cover Screw M6 x 16 70 8
Water Temperature Sensor Screw M6 x 16 70 8
Charging and Starting System
Starter Through Screw M6 x 120 70 8
Starter Solenoid Screw M6 x 52 70 8
Solenoid - Spade Connector N/A 78 9
Terminal Nut
Solenoid - Red Wire Terminal Nut N/A 70 8
Starter Motor Mounting Screw M8 x 45 156 13 18
Positive Battery Terminal Nut N/A 70
Negative Battery Terminal Screw M6 x 20 70 8
ELECTRONIC FUEL INJECTION
Intake and Intake Silencer
Intake Silencer Mounting Screw M6 x 16 70 8
Intake Assembly Mounting Screw M8 x 40 156 13 18
Intake Bracket Mounting Screw M6 x 20 70 8
Throttle Body
Throttle Body Mounting Screw M8 x 70 56 13 18
Throttle Body Bracket Screw M6 x 25 70 8
Accelerator Cam Nut N/A 70 8
Throttle Control Lever Mounting Screw M6 x 30 70 8
Fuel Injection
Fuel Rail Joint Screw M5 x 16 43 5
Fuel Rail Mounting Screw M8 x 45 13 18
Fuel Rail/Fuel Cooler Mounting Screw M6 x 25 70 8
Vapor Separator Mounting Screw M6 x 30 70 8
Pressure Regulator Screw M6 x 12 70 8
Idle Air Control Assembly M8 x 60 156 13 18
Mounting Screw M8 x 24

Page 1A-12 90-881980R1 NOVEMBER 2001

 SPECIFICATIONS

Fastener Location DIameter x Torque

Length (mm) lb-in. lb-ft. Nm
Manifold Absolute Pressure Sensor M5 x 15 43 5
Mounting Screw
Idle Air Control Mounting Screw M4 x 15 18 2
Throttle Position Sensor Tamper M4 x 12 18 2
Proof Screw
Bracket Tamper Proof Screw M5 x 12 40 5
Spark Plug Cover Screw M6 x 16 70 8
Fuel Filter Mounting Screw M6 x 16 70 8
Fuel Pump Mounting Screw M6 x 30 70 8
Fuel Pump Cover Screw M6 x 35 70 8
POWERHEAD
Cylinder Head
* Cylinder Head Screw M8 x 55 20 28
* Cylinder Head Screw M10 x 145 22 30
Head Cover Screws M6 x 30 70 8
Spark Plug Cover Screws M6 x 16 65 7.5
Anode Screw M6 x 20 70 8
Anode Cover Screw M8 x 25 156 13 18
Thermostat Screw M6 x 25 70 8
Camshaft/Oil Pump
* Camshaft Cap Screw N/A 150 17
Driven Sprocket Screw M10 x 35 44 60
Timing Belt Tensioner Screw M10 x 45 29.5 40
Cylinder Block/Crankcase
* Crankcase Cover Outer Screws M8 x 55 20 28
* Crankcase Cover Center Screws M8 135 14 19
* Exhaust Cover Screw M6 x 30 105 12
* Powerhead Mounting Nut N/A 35 47.5
* Powerhead Mounting Screw M8 x 35 20 27
* Connecting Rod Screw M8 x 38 132 11 15
Drive Sprocket Nut N/A 195 265
Powerhead/Oil Pump N/A
Powerhead Mounting Nut N/A 40 54.5
Powerhead Mounting Screw M8 x 35 20 27
Oil Pump Cover Screw M6 x 10 70 8
Oil Pick-up Tube Mounting Screw M6 x 20 100 11.5
Oil Pump Mounting Screw M6 x 45 85 9.5
NOTE: * = Must be tightened in sequence and/or multiple stages, and/or requires torque plus rotation.
See appropriate section of component for details.

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SPECIFICATIONS

Fastener Location DIameter x Torque

Length (mm) lb-in. lb-ft. Nm
MID-SECTION
Bottom Cowl/Adaptor Plate
Bottom Cowl Screw M6 x 40 65 7.5
Grommet Cover Screw M6 x 20 65 7.5
Oil Drain Plug N/A 17.5 24
Lower Mounting Bolt M12 X 154 50 68
Upper Mounting Bolt M12 x 154 55 75
Adaptor Plate Screw M8 x 50 25 34
Oil Sump/Adaptor Plate M6 x 35 100 11.5
Check Valve N/A 15 1.5
Exhaust Tube Screw M6 x 60 100 11.5
Adaptor Plate Screw M6 x 36 100 11.5
Shift Linkage Bracket/Adaptor Screw M6 x 20 80 9
Drive Shaft Housing/Lower Unit Nut N/A 40 54
Lower Mount Clamp Screw N/A 17 23
Front Handle Assembly Bolt M6 x 75 65 7.5
Power Trim
Shock Rod Piston N/A 90 122
Shock Piston Screw N/A 35 4
End Cap N/A 45 61
Trim Motor/Manifold Assembly Screw N/A 80 9
Pump/Motor Assembly Screw N/A 70 8
Pump Plug N/A 120 13.5
Manifold Screw N/A 100 11
Clamp/Swivel Bracket
Grease Fitting N/A 40 3.5 4.5
Swivel Bracket Screw 1/4–28 x 1/2 in. 100 11.5
Link Arm Nut 3/8 in. 120 13.5
Link Arm Bolt 3/8-28 x 1/2 in. 20 27
Anchor Bracket Screw M10 x 30 40 54
Anchor Bracket Nut M10 40 54
Tilt Tube Nut (Port) N/A Drive Tight
* Tilt Tube Nut (Starboard) N/A *
Anode Assembly Screw M6 x 25 60 7
* Shift Link Nut N/A *
NOTE: * = Drive Nut until Assembly is drawn together; but must be free to pivot.

Page 1A-14 90-881980R1 NOVEMBER 2001

 SPECIFICATIONS

Fastener Location DIameter x Torque

Length (mm) lb-in. lb-ft. Nm
LOWER UNIT
Gear Housing
Bearing Carrier Stud/Nut M8 x 48 225 25 34
Drive Shaft/Pinion Nut N/A 70 95
Water Pump Cover Screws M6 x 30 60 7
Water Pump Mounting Screw M6 x 25 60 7
Vent, Fill/Drain, Oil Level Screw N/A 60 7
Drive Shaft Housing/Lower Unit Nut N/A 40 54.2
Trim Tab Retaining Screw 7/16-14 x 1-1/4 22 30
in.
Propeller Nut N/A 55 75
Shift Shaft Bushing Assembly Screw M6 x 25 35 4
Anode Screw M6 x 40 60 7
CONTROL LINKAGE/
ATTACHMENTS
Throttle/Shift Linkage
Steering Cable Nut N/A 35 47.5
Throttle Lever Collar Nut N/A 70 8
Throttle Control Lever Mounting Bolt M6 x 30 70 8
Shift Bracket Screw M6 x 20 80 9

90-881980R1 NOVEMBER 2001 Page 1A-15